Additive Manufacturing Apparatus, System, and Method

ABSTRACT

An apparatus for producing a three-dimensional object includes a support assembly having a build platform, a track extending through a build area, and a deposition mechanism mounted on the track and configured for producing the three-dimensional object in a layer-by-layer technique. The deposition mechanism includes a carriage moveable along the track, a supply of a flowable material mounted on the carriage, a roller in communication with the flowable material, where the roller is rotatably mounted on the carriage and configured for rotating to carry the flowable resin to an application for application to produce the object, and an exposure device mounted on the carriage. The exposure device emits electromagnetic waves to an exposure site to solidify the applied flowable material to produce the object. The roller is permeable to the electromagnetic waves, such that the waves pass through the roller in traveling from the exposure device to the exposure site.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent applicationSer. No. 15/349,748, filed Nov. 11, 2016, and a continuation-in-part ofU.S. patent application Ser. No. 15/349,780, filed Nov. 11, 2016, bothof which prior applications claim priority to U.S. ProvisionalApplication No. 62/255,175, filed Nov. 13, 2015, all of whichapplications are incorporated by reference herein in their entireties.

TECHNICAL FIELD

The present disclosure generally relates to an apparatus and system forproducing a three-dimensional object in an additive manufacturingtechnique and method for operating the apparatus and system, and morespecifically, to an apparatus, system, and method that uses a roller incontact with a flowable resin or other precursor material in buildingeach layer of the object.

BACKGROUND

Current techniques for additive manufacturing of three-dimensionalobjects (e.g., stereolithography, 3-D printing, etc.) can produceexcellent quality products with high fidelity, but such techniques havesignificant limitations. Typically, such techniques work in one of threeways: (a) continually polymerizing layers at or near the surface ofliquid resin contained in a stationary vat, (b) continually polymerizinglayers of resin at or near the bottom of a stationary vat of resin, or(c) continually polymerizing layers of resin that has been jetteddownward by one or more single-nozzle or multi-nozzle print heads. Suchtechniques are generally limited to small sizes, with maximum sizes forvarious machines being only a few feet in width or length or evensmaller. This limits the size of objects that can be produced. Jet-basedprocesses have significant size limitations and waste a great deal ofresin material during production.

Vat-based techniques require that the object is partially or fullysubmerged during manufacturing, thus requiring the vat of resin to bemaintained at a significant volume. This can be costly, as such resinsare typically very expensive, and maintenance of resin vats in acollection of machines can be extremely costly. The size of the vat alsolimits the size of the object that can be produced, as noted above.Additionally, submersion of the object during production often resultsin cavities within the object being filled with uncured liquid resin,which must be drained, often requiring drilling a drainage hole andsubsequent repair. Further, the vat generally only contains a singleresin, so manufacture of multi-material parts is not possible. Vat-basedtechniques have production speed limitations as well, due to wait timesfor new resin to flow over or under the areas to be polymerized.

The present disclosure seeks to overcome certain of these limitationsand other drawbacks of existing apparatuses, systems, and methods, andto provide new features not heretofore available.

BRIEF SUMMARY

The following presents a general summary of aspects of the invention inorder to provide a basic understanding of the invention. This summary isnot an extensive overview of the invention. It is not intended toidentify key or critical elements of the invention or to delineate thescope of the invention. The following summary merely presents someconcepts of the invention and the disclosure in a general form as aprelude to the more detailed description provided below.

Aspects of the disclosure relate to an assembly for producing athree-dimensional object, including a support assembly including a buildplatform defining a build area for producing a three-dimensional objecton the build platform, a track extending through the build area, wherethe track has an open end, and a deposition mechanism engaged with thetrack. The deposition mechanism includes a carriage configured formovement along the track through the build area, a supply of a flowableresin mounted on the carriage, an applicator in communication with thesupply of flowable resin and configured for application of the flowableresin, and an exposure device mounted on the carriage and configured foremitting electromagnetic waves to solidify the flowable resin. Thedeposition mechanism also includes a track engagement mechanismconfigured for releasably engaging the track and moving the depositionmechanism along the track for producing the three-dimensional object.Additionally, the deposition mechanism is engageable with anddisengageable from the track by passing through the open end of thetrack, and the deposition mechanism further includes a ground engagementmechanism configured to move the deposition mechanism separately fromthe track when the deposition mechanism is disengaged from the track.

According to one aspect, the ground engagement mechanism includes wheelsconfigured for movement of the deposition mechanism separately from thetrack. The ground engagement mechanism may additionally or alternatelyinclude extendible stabilizers, where the stabilizers are configured tobe movable between an extended position for stabilizing the depositionmechanism when the deposition mechanism is disengaged from the track anda retracted position when the deposition mechanism is engaged with thetrack.

According to another aspect, the track includes first and second railson opposite sides of the build platform, where the first and secondrails are configured to be engaged by the deposition mechanism andsupport the deposition mechanism for movement through the build area,and where an opening is defined between the first and second rails atthe open end, such that the deposition mechanism can engage with anddisengage from the track by passing through the opening. In oneconfiguration, the track engagement mechanism includes rollersconfigured to engage inner and outer surfaces of the first and secondrails and gears configured to drive movement of the deposition mechanismalong the first and second rails.

According to a further aspect, the track extends below the buildplatform and the build area is defined below the build platform.

According to yet another aspect, the deposition mechanism may furtherinclude an onboard power source to power operation of the depositionmechanism and/or a processor configured to control movement of thecarriage and operation of the applicator and the exposure device in anautonomous manner, according to computer-executable instructions.

According to a still further aspect, the build platform is moveablebetween a build position and a tending position, where the buildplatform faces toward the track in the build position to permitproduction of the three dimensional object by the deposition mechanismlocated on the track, and where the build platform faces away from thetrack in the tending position to permit a tending operation to beperformed on the three dimensional object. In one configuration, thesupport assembly further includes a rotating base configured forrotation on an axis and a support platform extending from the rotatingbase in a direction parallel to the axis, where the build platform issupported by the support platform, and where the build platform ismoveable between the build position and the tending position by rotationof the rotating base, which causes the support platform to orbit theaxis.

Additional aspects of the disclosure relate to an assembly for producinga three-dimensional object, including a support assembly having a buildplatform defining a build area for producing a three-dimensional objecton the build platform, and a track extending through the build area,wherein the track is configured for supporting a moveable depositionmechanism to pass through the build area for producing thethree-dimensional object on the build platform using a flowable resin ina layer-by-layer technique. The track includes a bus bar configured forsupplying power to the deposition mechanism when the depositionmechanism is supported by the track. The apparatus may further includethe deposition mechanism, where the deposition mechanism includes acarriage configured for movement along the track, an applicator incommunication with the supply of flowable resin, where the applicator ismounted on the carriage and configured for applying the flowable resinto an application site within the build area to produce athree-dimensional object on the build platform as the carriage passesthrough the build area, and where the deposition mechanism has anelectrical contact configured for drawing power by contact with the busbar of the track.

According to one aspect, the deposition mechanism further includeswheels configured for autonomous movement of the deposition mechanismseparately from the track and/or a track engagement mechanism configuredfor releasably engaging the track, such that the deposition mechanism isconfigured for movement by the wheels separately from the track and thedeposition mechanism is further configured for movement by the trackengagement mechanism along the track for producing the three-dimensionalobject.

According to another aspect, the track includes first and second railson opposite sides of the build platform, where the first and secondrails are configured to be engaged by the deposition mechanism andsupport the deposition mechanism for movement through the build area,and where the bus bar is connected to one of the first and second rails.In one configuration, the track further includes a second bus barconnected to the other of the first and second rails.

According to a further aspect, the track extends below the buildplatform and the build area is defined below the build platform.

Further aspects of the disclosure relate to an assembly for producing athree-dimensional object, including a support assembly having a buildplatform defining a build area for producing a three-dimensional objecton the build platform and a track extending through the build area. Thetrack is configured for supporting a moveable deposition mechanism topass through the build area for producing the three-dimensional objecton the build platform using a flowable resin in a layer-by-layertechnique. The build platform is moveable between a build position and atending position, where the build platform faces toward the track in thebuild position to permit production of the three dimensional object bythe deposition mechanism located on the track, and where the buildplatform faces away from the track in the tending position to permit atending operation to be performed on the three dimensional object.

According to one aspect, the support assembly further includes arotating base configured for rotation on an axis and a support platformextending from the rotating base in a direction parallel to the axis,where the build platform is supported by the support platform, and wherethe build platform is moveable between the build position and thetending position by rotation of the rotating base, which causes thesupport platform to orbit the axis. In one configuration, the rotatingbase is positioned at a first end of the support platform, and thesupport assembly further includes a second rotating base at a second endof the support platform opposite the first end. The second rotating baseis also configured for rotation on the axis, such that the rotating baseand the second rotating base rotate in unison to move the build platformbetween the build position and the tending position. In an additionalconfiguration, the rotating base is configured to rotate 180° in movingthe build platform between the build position and the tending position.

According to another aspect, the build platform is moveable between thebuild position and the tending position by rotation.

According to a further aspect, the assembly further includes thedeposition mechanism, where the deposition mechanism includes a carriageconfigured for movement along the track, an applicator in communicationwith the supply of flowable resin, where the applicator is mounted onthe carriage and configured for applying the flowable resin to anapplication site within the build area to produce a three-dimensionalobject on the build platform as the carriage passes through the buildarea.

According to yet another aspect, the track extends below the buildplatform and the build area is defined below the build platform.

According to a still further aspect, the build platform may further bemoveable between the build position and a plurality of tendingpositions, where the build platform faces at different orientations ineach of the plurality of tending positions. The movement and/ororientation of the build platform in the tending position(s) may bemanually controlled by a user in one configuration.

Still further aspects of the disclosure relate to an assembly forproducing a three-dimensional object, including a carriage configuredfor movement through a build area defined by a build platform, a supplyof a flowable resin mounted on the carriage, a roller in communicationwith the supply of flowable resin, and an exposure device mounted on thecarriage and configured for emitting electromagnetic waves through anoutlet toward an exposure site within the build area to solidify appliedresin applied by the roller to produce the three-dimensional object. Theroller is rotatably mounted on the carriage and configured for rotatingto carry the flowable resin to an application site within the build areafor application to produce the three-dimensional object as the carriagepasses through the build area, where the roller and the supply offlowable resin are provided as a resin application module that isremovable from the carriage and replaceable with a second resinapplication module.

According to one aspect, the supply of flowable resin includes areservoir, and the roller is at least partially disposed within thereservoir to be in communication with the supply of flowable resin. Inone configuration, the roller is elongated between first and secondends, and where the first end of the roller is connected to a side wallof the reservoir. In an additional configuration, the roller ispermeable to the electromagnetic waves, and the outlet of the exposuredevice is positioned within the roller such that the electromagneticwaves pass through the roller in traveling from the outlet to theapplied resin, and the outlet of the exposure device is configured to beremoved from within the roller when the resin application module isremoved from the carriage. In a further configuration, the outlet of theexposure device is defined by an array of optical fibers having endslocated within the roller, and the optical fibers pass through the sidewall of the reservoir to enter the roller through the first end.

According to another aspect, the carriage includes a track engagementmechanism configured for releasably engaging a track passing through thebuild area, such that the carriage is configured for movement by thetrack engagement mechanism along the track for producing thethree-dimensional object.

Still further aspects of the disclosure relate to an assembly orapparatus for producing a three-dimensional object, including a carriageconfigured for movement through a build area defined by a buildplatform, a supply of a flowable resin mounted on the carriage, anapplicator in communication with the supply of flowable resin, avertical adjustment mechanism configured for adjusting a verticalposition of the applicator relative to the carriage, and an exposuredevice mounted on the carriage and configured for emittingelectromagnetic waves through an outlet toward an exposure site withinthe build area to solidify applied resin applied by the roller toproduce the three-dimensional object. The applicator is mounted on thecarriage and configured for applying the flowable resin to anapplication site within the build area to produce a three-dimensionalobject on the build platform as the carriage passes through the buildarea.

According to one aspect, the apparatus is automated, such that thecarriage has a processor configured to control movement of the carriageaccording to computer-executable instructions. In one configuration, thecarriage has a memory storing the computer-executable instructions. Inan additional configuration, the carriage has a receiver configured forreceiving the computer-executable instructions from an external deviceand a transmitter configured for transmitting information to theexternal device.

According to another aspect, the vertical adjustment mechanism isfurther configured for adjusting a vertical position of the supply andthe outlet of the exposure device along with the applicator as a singleunit.

According to a further aspect, the carriage has wheels configured formoving on a flat surface and a track engagement mechanism configured forengaging a track that extends through the build area and moving thecarriage along the track.

According to yet another aspect, the carriage has a track engagementmechanism configured for engaging a track that extends through the buildarea and moving the carriage along the track, and the track engagementmechanism may further include electrical contacts to permit theapparatus to draw electrical power from the track in a bus arrangement.

Additional aspects of the disclosure relate to an assembly or apparatusfor producing a three-dimensional object, including a carriageconfigured for movement through a build area defined by a buildplatform, a supply of a flowable resin mounted on the carriage, and anapplicator in communication with the supply of flowable resin. Theroller is rotatably mounted on the carriage and configured for rotatingto carry the flowable resin to an application site within the build areafor application to produce a three-dimensional object on the buildplatform as the carriage passes through the build area. The apparatusfurther includes an exposure device mounted on the carriage andconfigured for emitting electromagnetic waves through an outlet towardan exposure site within the build area to solidify applied resin appliedby the roller to produce the three-dimensional object, and a processorconfigured to control movement of the carriage and operation of theapplicator and the exposure device in an autonomous manner, according tocomputer-executable instructions.

According to one aspect, the apparatus further includes a memory storingthe computer-executable instructions.

According to another aspect, the computer-executable instructionsfurther include instructions for producing the three-dimensional objectin a layer-by-layer configuration.

According to a further aspect, the apparatus includes a receiverconfigured for receiving the computer-executable instructions from anexternal device and a transmitter configured for transmittinginformation to the external device.

According to yet another aspect, the carriage has wheels for moving on aflat surface and a track engagement mechanism configured for engaging atrack that extends through the build area and moving the carriage alongthe track.

According to a still further aspect, the carriage has a track engagementmechanism configured for engaging a track that extends through the buildarea and moving the carriage along the track, and the track engagementmechanism further includes electrical contacts to permit the apparatusto draw electrical power from the track in a bus arrangement.

According to an additional aspect, the apparatus includes a verticaladjustment mechanism configured for adjusting a vertical position of theapplicator relative to the carriage.

Additional aspects of the disclosure relate to an assembly or apparatusfor producing a three-dimensional object, including a carriageconfigured for movement through a build area defined by a buildplatform, a supply of a flowable resin mounted on the carriage, and anapplicator in communication with the supply of flowable resin, where theapplicator is mounted on the carriage and configured for applying theflowable resin to an application site within the build area to produce athree-dimensional object on the build platform as the carriage passesthrough the build area. The apparatus also includes an exposure devicemounted on the carriage and configured for emitting electromagneticwaves through an array of outlets toward an exposure site within thebuild area to solidify applied resin applied by the applicator toproduce the three-dimensional object, where the array of outlets isarranged in a laterally-extending staggered arrangement, such that eachoutlet of the array of outlets is laterally overlapped by at least oneother outlet.

According to one aspect, the staggered arrangement includes at least twoparallel rows of outlets that are laterally offset from each other.

According to another aspect, the applicator includes a roller incommunication with the supply of flowable resin, where the roller isrotatably mounted on the carriage and configured for rotating to carrythe flowable resin to the application site. In one configuration, theroller is permeable to the electromagnetic waves, and the array ofoutlets is positioned within the roller such that the electromagneticwaves pass through the roller in traveling from the outlets to theapplied resin.

According to a further aspect, the applicator is configured for applyingthe flowable resin to the application site within the build area whenthe build area is located above the applicator.

Additional aspects of the disclosure relate to an assembly or apparatusfor producing a three-dimensional object, including a carriageconfigured for movement through a build area defined by a buildplatform, a supply of a flowable resin mounted on the carriage, and anapplicator in communication with the supply of flowable resin, where theapplicator is mounted on the carriage and configured for applying theflowable resin to an application site within the build area to produce athree-dimensional object on the build platform as the carriage passesthrough the build area. The apparatus further includes an exposuredevice mounted on the carriage and configured for emittingelectromagnetic waves through an array of outlets toward an exposuresite within the build area to solidify applied resin applied by theapplicator to produce the three-dimensional object, where the exposuredevice is configured for varying the power output of the electromagneticwaves in order to adjust an exposure size of at least one of theoutlets.

Additional aspects of the disclosure relate to an assembly or apparatusfor producing a three-dimensional object, including a carriageconfigured for movement through a build area defined by a buildplatform, a supply of a flowable resin mounted on the carriage, and anapplicator in communication with the supply of flowable resin, whereinthe applicator is mounted on the carriage and configured for applyingthe flowable resin to an application site within the build area toproduce a three-dimensional object on the build platform as the carriagepasses through the build area. The apparatus further includes anexposure device mounted on the carriage and configured for emittingelectromagnetic waves through a first outlet and a second outlet towardan exposure site within the build area to solidify applied resin appliedby the applicator to produce the three-dimensional object, where theexposure device is configured for emitting the electromagnetic wavesthrough the first outlet at a first power level and emitting theelectromagnetic waves through the second outlet at a second power levelthat is greater than the first power level.

According to one aspect, the exposure device is configured for emittingthe electromagnetic waves alternately through the first outlet or thesecond outlet.

According to another aspect, the exposure device is configured foremitting the electromagnetic waves through a plurality of first outletsat the first power level and through a plurality of second outlets atthe second power level, where the first outlets are arranged in a firstrow and the second outlets are arranged in a second row parallel to thefirst row.

Additional aspects of the disclosure relate to an assembly or apparatusfor producing a three-dimensional object, including a carriageconfigured for movement through a build area defined by a buildplatform, a supply of a flowable resin mounted on the carriage, and anapplicator in communication with the supply of flowable resin, where theapplicator is mounted on the carriage and configured for applying theflowable resin to an application site within the build area to produce athree-dimensional object on the build platform as the carriage passesthrough the build area. The apparatus further includes an exposuredevice mounted on the carriage and configured for emittingelectromagnetic waves selectively through a first outlet or a secondoutlet toward an exposure site within the build area to solidify appliedresin applied by the applicator to produce the three-dimensional object,where the exposure device includes a first wave source configured toemit a first type of the electromagnetic waves through the first outletand a second wave source configured to emit a second type of theelectromagnetic waves through the second outlet.

According to one aspect, the exposure device is further configured foremitting electromagnetic waves selectively through the first outlet, thesecond outlet, or a third outlet toward the exposure site within thebuild area, and the exposure device includes a third wave sourceconfigured to emit a third type of the electromagnetic waves through thethird outlet.

According to another aspect, the exposure device further includes amechanical switching mechanism for selectively directing the firstoutlet, the second outlet, or the third outlet toward the exposure sitewithin the build area.

Additional aspects of the disclosure relate to an assembly or apparatusfor producing a three-dimensional object, including a carriageconfigured for movement in a travel direction through a build areadefined by a build platform, a supply of a flowable resin mounted on thecarriage, and an applicator in communication with the supply of flowableresin, where the applicator is mounted on the carriage and configuredfor applying the flowable resin to an application site within the buildarea to produce a three-dimensional object on the build platform as thecarriage passes through the build area. The apparatus also includes anexposure device mounted on the carriage and configured for emittingelectromagnetic waves through an outlet toward an exposure site withinthe build area to solidify applied resin applied by the applicator toproduce the three-dimensional object, where the exposure device includesan aim adjustment mechanism configured for adjusting an aim of theoutlet in the travel direction during application of the resin to permitthe aim of the outlet to be focused on a defined point within the buildarea as the applicator passes the defined point.

Other aspects of the disclosure relate to systems that include anassembly apparatus as described above, with a computer controllerconfigured for controlling one or more operations of the assembly orapparatus to produce the object.

Other aspects of the disclosure relate to methods of operating thesystems and apparatuses described above to produce a three-dimensionalobject. For example, aspects of the disclosure relate to a method usedin connection with an apparatus provided that includes a supportassembly comprising a build platform defining a build area, a trackextending through the build area, and a deposition mechanism mounted onthe track, the deposition mechanism including a carriage configured formovement along the track through the build area, a supply of a flowableresin mounted on the carriage, an applicator in communication with thesupply of flowable resin and configured for application of the flowableresin, and an exposure device mounted on the carriage and configured foremitting electromagnetic waves. The build platform is moveable between abuild position and a tending position, where the build platform facestoward the track in the build position, and where the build platformfaces away from the track in the tending position. The method alsoincludes moving the deposition mechanism through the build area alongthe track while the build platform is in the build position, andapplying the flowable resin to an application site within the buildarea, using the applicator, to produce first and secondthree-dimensional objects simultaneously on the build platform in alayer-by-layer technique as the carriage passes through the build area.The method further includes selectively activating the exposure deviceto emit the electromagnetic waves toward an exposure site within thebuild area to solidify applied resin applied by the applicator toproduce the first and second three-dimensional objects simultaneously,moving the build platform from the build position to the tendingposition, removing the first three-dimensional object from the buildplatform while the build platform is in the tending position, returningthe build platform to the build position with the secondthree-dimensional object still supported by the build platform, andcontinuing production of the second three-dimensional object by movingthe deposition mechanism through the build area along the track whilethe build platform is in the build position, and applying the flowableresin to an application site within the build area, using theapplicator, to produce the second three-dimensional object on the buildplatform in a layer-by-layer technique as the carriage passes throughthe build area.

According to one aspect, the support assembly further includes arotating base configured for rotation on an axis and a support platformextending from the rotating base in a direction parallel to the axis,where the build platform is supported by the support platform, and wheremoving the build platform between the build position and the tendingposition is performed by rotating the rotating base, which causes thesupport platform to orbit the axis. In one configuration, the rotatingbase is positioned at a first end of the support platform, and thesupport assembly further includes a second rotating base at a second endof the support platform opposite the first end, where the secondrotating base is also configured for rotation on the axis, such that therotating base and the second rotating base rotate in unison to move thebuild platform between the build position and the tending position. Inan additional configuration, the rotating base rotates 180° in movingthe build platform between the build position and the tending position.

According to another aspect, the build platform moves between the buildposition and the tending position by rotating.

According to a further aspect, the track extends below the buildplatform and the build area is defined below the build platform, suchthat the build platform faces downward in the build position and facesupward in the tending position.

According to yet another aspect, the method further includes connectingthe first three-dimensional object to the second three-dimensionalobject while the build platform is in the tending position.

Additional aspects of the disclosure relate to a method that is usablewith a provided apparatus that includes a support assembly including abuild platform defining a build area for producing a three-dimensionalobject on the build platform, a track extending through the build area,and a deposition mechanism mounted on the track, the depositionmechanism including a carriage configured for movement along the trackthrough the build area, a supply of a flowable resin mounted on thecarriage, an applicator in communication with the supply of flowableresin and configured for application of the flowable resin, and anexposure device mounted on the carriage and configured for emittingelectromagnetic waves. The build platform is moveable between a buildposition and a tending position, where the build platform faces towardthe track in the build position, and the build platform faces away fromthe track in the tending position. The method includes moving thedeposition mechanism through the build area along the track while thebuild platform is in the build position, and applying the flowable resinto an application site within the build area, using the applicator, toproduce the three-dimensional object on the build platform in alayer-by-layer technique as the carriage passes through the build area.The method also includes selectively activating the exposure device toemit the electromagnetic waves toward an exposure site within the buildarea to solidify applied resin applied by the applicator to produce thethree-dimensional object. The method further includes moving the buildplatform from the build position to the tending position, performing atending operation on the three dimensional object, returning the buildplatform to the build position with the three-dimensional object stillsupported by the build platform, and continuing production of thethree-dimensional object using the apparatus.

According to one aspect, the support assembly further includes arotating base configured for rotation on an axis and a support platformextending from the rotating base in a direction parallel to the axis,where the build platform is supported by the support platform, and wheremoving the build platform between the build position and the tendingposition is performed by rotating the rotating base, which causes thesupport platform to orbit the axis. In one configuration, the rotatingbase is positioned at a first end of the support platform, and thesupport assembly further includes a second rotating base at a second endof the support platform opposite the first end. The second rotating baseis also configured for rotation on the axis, such that the rotating baseand the second rotating base rotate in unison to move the build platformbetween the build position and the tending position. In an additionalconfiguration, the rotating base rotates 180° in moving the buildplatform between the build position and the tending position.

According to another aspect, the build platform moves between the buildposition and the tending position by rotating.

According to a further aspect, the track extends below the buildplatform and the build area is defined below the build platform, suchthat the build platform faces downward in the build position and facesupward in the tending position.

According to a still further aspect, the tending operation includesconnecting a secondary component to the three-dimensional object. In oneconfiguration, the secondary component is connected in a configurationsuch that the secondary component is not exposed to the electromagneticwaves during the continuing production of the three-dimensional object.

Further aspects of the disclosure relate to a method that is usable witha provided apparatus that includes a support assembly including a buildplatform defining a build area for producing a three-dimensional objecton the build platform, a track extending through the build area, and adeposition mechanism mounted on the track, the deposition mechanismincluding a carriage configured for movement along the track through thebuild area, a supply of a flowable resin mounted on the carriage, anapplicator in communication with the supply of flowable resin andconfigured for application of the flowable resin, and an exposure devicemounted on the carriage and configured for emitting electromagneticwaves. The method includes moving the deposition mechanisms through thebuild area sequentially in a first pass along the track while the buildplatform is in the build position to produce the three-dimensionalobject on the build platform in a layer-by-layer technique as eachcarriage passes through the build area. This action involves applyingthe flowable resin to an application site within the build area, usingthe applicator of each deposition mechanism, and selectively activatingthe exposure devices of each deposition mechanism to emit theelectromagnetic waves toward an exposure site within the build area tosolidify applied resin applied by the applicator to produce thethree-dimensional object.

According to one aspect, each deposition mechanism applies a separatelayer of the three-dimensional object in the first pass.

According to another aspect, at least two of the deposition mechanismsapply different portions of a same layer of the three-dimensional objectin the first pass.

According to a further aspect, the method also includes moving thedeposition mechanisms through the build area sequentially in pluralityof additional passes along the track while the build platform is in thebuild position to produce the three-dimensional object on the buildplatform.

According to yet another aspect, the method also includes moving thedeposition mechanisms through the build area sequentially along thetrack while the build platform is in the build position produces asecond three-dimensional object on the build platform in thelayer-by-layer technique as each carriage passes through the build areasimultaneously with the three-dimensional object.

Further aspects of the disclosure relate to a method that is usable witha provided apparatus that includes a carriage configured for movementthrough a build area defined by a build platform, a supply of a flowableresin mounted on the carriage, an applicator in communication with thesupply of flowable resin, where the applicator is mounted on thecarriage and configured for applying the flowable resin, and an exposuredevice mounted on the carriage and configured for emittingelectromagnetic waves through an array of outlets. The method includesmoving the carriage through the build area, and applying the flowableresin to an application site within the build area, using theapplicator, to produce a three-dimensional object on the build platformin a layer-by-layer technique as the carriage passes through the buildarea. The method also includes selectively activating the exposuredevice to emit the electromagnetic waves toward an exposure site withinthe build area to solidify applied resin applied by the applicator toproduce the three-dimensional object simultaneously, where selectivelyactivating the exposure device comprises varying the power output of theelectromagnetic waves in order to adjust an exposure size of at leastone of the outlets.

Other features and advantages of the invention will be apparent from thefollowing description taken in conjunction with the attached drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

To understand the present invention, it will now be described by way ofexample, with reference to the accompanying drawings in which:

FIG. 1 is a side schematic view of one embodiment of a system andapparatus for producing a three-dimensional object in operation,according to aspects of the disclosure;

FIGS. 2A and 2B are side schematic views of a support assembly of thesystem and apparatus of FIG. 1, with a three-dimensional object producedon the support assembly;

FIG. 3 is a side schematic view of another embodiment of a system andapparatus for producing a three-dimensional object in operation,according to aspects of the disclosure;

FIG. 4 is a side schematic view of another embodiment of a system andapparatus for producing a three-dimensional object in operationaccording to aspects of the disclosure;

FIGS. 5A and 5B are top schematic views of the system and apparatus ofFIG. 1 in operation, according to aspects of the present disclosure;

FIGS. 6A and 6B are side schematic views of the system and apparatus ofFIG. 1 in operation, according to aspects of the present disclosure;

FIG. 7 is a side schematic view of the apparatus of FIG. 1, furtherincluding a secondary exposure device;

FIG. 8 is a top perspective view of another embodiment of an apparatusfor producing a three-dimensional object, according to aspects of thedisclosure;

FIG. 9 is a side view of the apparatus as shown in FIG. 8;

FIG. 10 is a top perspective view of a deposition mechanism of theapparatus as shown FIG. 8;

FIG. 11 is a top view of the deposition mechanism of the apparatus asshown in FIG. 10;

FIG. 12 is a perspective view of one embodiment of a collector for usewith the deposition mechanism of FIG. 8, according to aspects of thedisclosure;

FIG. 13 is a schematic view of the collector of FIG. 12 shown inoperation with one embodiment of an exposure device according to aspectsof the disclosure;

FIG. 14 is a side schematic view of another embodiment of an exposuredevice according to aspects of the disclosure;

FIG. 15 is a perspective view of another embodiment of an apparatus forproducing a three-dimensional object in operation, according to aspectsof the disclosure;

FIG. 16 is a side view of a deposition mechanism of the apparatus ofFIG. 15;

FIG. 17 is an exploded view of the deposition mechanism of FIG. 16;

FIG. 18 is a perspective view of the deposition mechanism of FIG. 16;

FIG. 19 is a side schematic view of another embodiment of a depositionmechanism configured for modular connection of modular connection ofcomponents, according to aspects of the disclosure;

FIGS. 20A and 20B are side schematic views of another embodiment of anapparatus for producing a three-dimensional object in operation,according to aspects of the disclosure;

FIG. 21 is a side schematic view of another embodiment of an apparatusfor producing a three-dimensional object in operation, according toaspects of the disclosure;

FIG. 22 is a side schematic view of another embodiment of an apparatusfor producing a three-dimensional object in operation, according toaspects of the disclosure;

FIG. 23 is a side schematic view of another embodiment of an apparatusfor producing a three-dimensional object in operation, according toaspects of the disclosure;

FIG. 24A is a side schematic view of another embodiment of an apparatusfor producing a three-dimensional object in operation, according toaspects of the disclosure;

FIG. 24B is a side schematic view of another embodiment of an apparatusfor producing a three-dimensional object in operation, according toaspects of the disclosure;

FIG. 25 is a side schematic view of another embodiment of a system andapparatus for producing a three-dimensional object in operation,according to aspects of the disclosure;

FIG. 26 is a schematic view of a controller according to aspects of thedisclosure;

FIG. 27 is a top schematic view of another embodiment of an applicatorand a supply of flowable material according to aspects of thedisclosure;

FIG. 28 is a side schematic view of another embodiment of a system andapparatus for producing a three-dimensional object in operation,according to aspects of the disclosure; and

FIG. 29 is a side schematic view of another embodiment of an apparatusfor producing a three-dimensional object in operation, according toaspects of the disclosure;

FIG. 30 is a side schematic view of another embodiment of an apparatusfor producing a three-dimensional object in operation, according toaspects of the disclosure;

FIG. 31 is a side view of another embodiment of an apparatus forproducing a three-dimensional object in operation, according to aspectsof the disclosure;

FIG. 32 is a perspective view of the apparatus of FIG. 31;

FIG. 33 is a perspective view of the apparatus of FIG. 31, showingvertical adjustment of a deposition mechanism of the apparatus to a newvertical application location;

FIG. 34 is a perspective view of a support assembly of the apparatus ofFIG. 31, showing movement of a build platform from a build position to atending position;

FIG. 35 is a perspective view of a support assembly of the apparatus ofFIG. 31, showing the build platform in the tending position;

FIG. 36 is a perspective view of the apparatus of FIG. 31 illustratingperformance of a tending operation when the build platform is in thetending position;

FIG. 37 is a perspective view of the apparatus of FIG. 31 illustratingfurther production of objects when the build platform is in the buildposition, after performance of the tending operation in FIG. 36;

FIG. 38 is a side view of the deposition mechanism of the apparatus ofFIG. 31;

FIG. 39 is a side view of the deposition mechanism of FIG. 38, showingvertical adjustment of the deposition mechanism to a new verticalapplication location;

FIG. 40 is a partial perspective view of the deposition mechanism ofFIG. 31, showing movement of the deposition mechanism separately of thesupport assembly;

FIG. 41A is a partial perspective view of the deposition mechanism ofFIG. 40 preparing to engage with a track of the support assembly;

FIG. 41B is a partial perspective view of the deposition mechanism ofFIG. 41 after engaging with the track of the support assembly;

FIG. 42 is a side view of the apparatus of FIG. 31 with multipledeposition mechanisms operating simultaneously;

FIG. 43 is a perspective view of a portion of a removable resinapplication module of the deposition mechanism of FIG. 38;

FIG. 44 is a perspective view illustrating removal of a resinapplication module from the resin deposition mechanism of FIG. 38;

FIG. 45 is a perspective view illustrating removal of the resinapplication module of FIG. 44 from the resin deposition mechanism ofFIG. 38;

FIG. 46 is a perspective view illustrating interchanging of a secondresin application module for the resin deposition mechanism of FIG. 38;

FIG. 47 is a perspective view of the deposition mechanism of FIG. 10illustrating removal of a resin application module from the depositionmechanism;

FIGS. 48A and 48B are side schematic views of another embodiment of anapparatus for producing a three-dimensional object in operation,according to aspects of the disclosure;

FIGS. 49A and 49B are rear schematic views of another embodiment of anapparatus for producing a three-dimensional object in operation,according to aspects of the disclosure;

FIGS. 49C and 49D are side schematic views of another embodiment of anapparatus for producing a three-dimensional object in operation,according to aspects of the disclosure;

FIG. 50 is a side schematic view of one embodiment of a buildup sensorconfigured for use in connection with a deposition mechanism forproducing a three-dimensional object in operation, according to aspectsof the disclosure;

FIG. 51 is a side schematic view of another embodiment of an apparatusfor producing a three-dimensional object in operation, according toaspects of the disclosure;

FIG. 52 is a side schematic view illustrating operation of the apparatusof FIG. 51 away from a build platform;

FIG. 53 is a side schematic view of another embodiment of an apparatusfor producing a three-dimensional object in operation, according toaspects of the disclosure;

FIG. 54 is a plan schematic view of one embodiment of an exposure devicefor use in connection with an apparatus for producing athree-dimensional object in operation, according to aspects of thedisclosure;

FIG. 55 is a plan schematic view of another embodiment of an exposuredevice for use in connection with an apparatus for producing athree-dimensional object in operation, according to aspects of thedisclosure;

FIG. 56 is a plan schematic view of another embodiment of an exposuredevice for use in connection with an apparatus for producing athree-dimensional object in operation, according to aspects of thedisclosure;

FIG. 57 is a plan schematic view of another embodiment of an exposuredevice for use in connection with an apparatus for producing athree-dimensional object in operation, according to aspects of thedisclosure;

FIG. 58 is a side schematic view of another embodiment of an exposuredevice and an applicator for use in connection with an apparatus forproducing a three-dimensional object in operation, according to aspectsof the disclosure;

FIG. 59 is a side schematic view illustrating one embodiment ofoperation of the exposure device and applicator of FIG. 58 in connectionwith an apparatus for producing a three-dimensional object in operation,according to aspects of the disclosure;

FIG. 60 is a side schematic view illustrating another embodiment ofoperation of the exposure device and applicator of FIG. 58 in connectionwith an apparatus for producing a three-dimensional object in operation,according to aspects of the disclosure;

FIGS. 61A and 61B are side schematic views of another embodiment of anexposure device and an applicator for use in connection with anapparatus for producing a three-dimensional object in operation,according to aspects of the disclosure;

FIG. 62 is a perspective view illustrating another embodiment of anapparatus for producing a three-dimensional object in operation,according to aspects of the disclosure, shown with a build platform in abuild position;

FIG. 63 is a perspective view illustrating the apparatus of FIG. 62showing movement of the build platform from the build position to atending position;

FIG. 64 is a perspective view illustrating the apparatus of FIG. 62showing the build platform in the tending position;

FIG. 65 is a schematic view illustrating a process for relocating andsolidifying additional material according to aspects of the disclosure;and

FIG. 66 is a partially-magnified schematic view of another embodiment ofan exposure device and a deposition mechanism according to aspects ofthe disclosure, with the exposure device shown magnified and a breakline illustrating separation between the magnified and non-magnifiedportions.

DETAILED DESCRIPTION

While this invention is capable of embodiment in many different forms,there are shown in the drawings, and will herein be described in detail,certain embodiments of the invention with the understanding that thepresent disclosure is to be considered as an example of the principlesof the invention and is not intended to limit the broad aspects of theinvention to the embodiments illustrated and described.

In general, the disclosure relates to systems, apparatuses, and methodsfor producing three-dimensional objects in a layer-by-layer technique,such as additive manufacturing, 3-D printing, stereolithography, orother rapid prototyping techniques. Referring first to FIG. 1, there isschematically shown an example embodiment of a system 10 that includes amanufacturing apparatus 12 and a computer controller 100 incommunication with one or more components of the apparatus 12 andconfigured for controlling operation of the apparatus 12 and/or thecomponents thereof to manufacture an object 11. The apparatus 12includes a support assembly 20 for supporting the object 11 within abuild area 13 during manufacturing, a track 14 extending through thebuild area 13, and a material deposition mechanism 30 mounted on thetrack 14 and configured for producing the object 11 within the buildarea 13 through layer-by-layer application of a material. The materialapplied by the deposition mechanism 30 may be any flowable material(e.g., liquids, powders or other particulate solids, and combinationsthereof) that are capable of being solidified to manufacture the object11, such as by polymerization, phase change, sintering, and othertechniques or combinations of such techniques. In one example, thematerial may be or include a resin that can be polymerized by exposureto electromagnetic waves such as light (visible, IR, or UV). When usinga resin-based material for manufacturing, the deposition mechanism 30may be referred to as a “resin deposition mechanism”. FIGS. 3-4 and 25illustrate additional schematic embodiments of the system 10 andapparatus 12, and FIGS. 8-13, and 15-19 illustrate structuralembodiments of the apparatus 12. FIGS. 2A-B, 5A-7, 14, and 20-29illustrate schematic embodiments of components and/or methods andconfigurations for operation of the system 10 and apparatus 12.Consistent reference numbers are used throughout this description torefer to structurally or functionally similar or identical componentsthroughout the drawing figures, and it is understood that features andaspects of some embodiments that have already been described insufficient detail may not be specifically re-described with respect toeach embodiment for the sake of brevity.

Production of objects 11 through additive manufacturing often involvesthe production of support structure, which is formed duringmanufacturing and supports the object 11 during manufacturing, to beremoved later. Such support structure can be formed of the same or adifferent material from the desired final portions of the object 11.Removal of such support structures can be accomplished using mechanicalmeans (e.g., separation, breakage, machining), solvent-based means(e.g., use of a water-soluble polymer that can be washed away), or othermeans. Any support structure manufactured along with an object 11 asdescribed herein will be considered to be part of the “object” asdefined herein.

The support assembly 20 generally includes at least a build platform 22that is configured to support the object 11 within the build area 13during manufacturing. The build area 13 is defined in the area adjacentto the build platform 22, which is immediately below the build platform22 in the embodiment of FIG. 1. The support assembly 20 in FIG. 1includes a support platform 24 that is movable in the vertical (z)direction and supports a removable insert 26 that defines the buildplatform 22. The insert 26 may be removably connected to the supportassembly 20 by mechanical connectors, such as clamps 28 as shown inFIGS. 2A and 2B or other mechanical structures, or various otherremovable connection mechanisms such as vacuum suction, magneticattraction, releasable adhesive, and combinations of such mechanisms incertain embodiments. In one embodiment, as shown in FIGS. 2A and 2B, theinsert 26 is removably connected to the support assembly 20 primarily byapplication of vacuum suction by a vacuum apparatus 21, with clamps 28used as a backup or redundant connection structure in case ofmalfunction, power outage, etc. As shown in FIG. 2A, when the object 11is to be supported by the support assembly 20, such as duringmanufacturing, the vacuum apparatus 21 applies suction to the insert 26and the clamps 28 are closed to retain the insert 26 in connection withthe support platform 24. As shown in FIG. 2B, when the object 11 is tobe removed, the vacuum suction is ceased and the clamps 28 are releasedin order to permit removal of the insert 26 and the object 11 from thesupport assembly 20. The insert 26 may be flexible, in order to easerelease of the object 11 from the insert 26 after removal. Further, itis understood that other removable configurations for the build platform22 may exist, and may or may not use a definable support platform 24.For example, in the embodiments of FIGS. 8-11 and 15-19, the entiresupport platform 24 is removable to permit removal of the build platform22 from the support assembly 20. It is also understood that the object11 may be removed from the build platform 22 without removal of thebuild platform 22, and that the build platform 22 may include noremovable structure in other embodiments.

In one embodiment, the support assembly 20 and the track 14 may bepartially or completely modular. The support assembly 20 and track 14 inthe embodiment of FIGS. 8-11 are configured in this manner. This permitsease of build-out and modification of the entire apparatus 12 asdesired. This also permits assembling or disassembling the apparatus 12to move it into or out of a room, even if the apparatus 12 issignificantly larger than the door to the room, which can be an issuewith current stereolithography machines.

The support assemblies 20 in the embodiments of FIGS. 8-11 and 15-19include vertical positioning mechanisms 23 that are configured to changethe height of the build platform 22 during manufacturing, as describedelsewhere herein. In the embodiment shown in FIG. 8, the verticalpositioning mechanism 23 includes multiple jack screws 25 positioned atopposite sides of the support assembly 20 and a support frame 27 thatengages the jack screws 25 and connects to and supports the supportplatform 24. Vertical movement of the support platform 24 (and thereby,the build platform 22) is accomplished by rotation of the jack screws25, and it is understood that the threading of the jack screws 25 may beangled to permit fine incremental changes in the vertical position ofthe build platform 22. The rotation of the jack screws 25 may be drivenby a motor assembly (not shown) and controlled by the controller 100. Inthe embodiment of FIG. 15, the vertical positioning mechanism 23includes four vertical drive mechanisms 29 located at four corners ofthe support assembly 20, with a support frame 27 that engages thevertical drive mechanisms 29 and connects to and supports the supportplatform 24. The vertical drive mechanisms 29 in FIG. 15 may be jackscrews as described herein, or may use a different mechanical structure,such as chains, cables, belts, gears, sprockets, wheels, etc. Thevertical drive mechanisms 29 may be driven by a motor assembly (notshown) and controlled by the controller 100.

FIG. 1 schematically illustrates an embodiment of the depositionmechanism 30, which generally includes a carriage 32 engaged with thetrack 14 and configured for movement along the track 14 and through thebuild area 13, a supply 34 of a flowable material 36 mounted on orotherwise operably connected to the carriage 32, an applicator 40 incommunication with the supply 34 of the flowable material 36 andconfigured to apply the flowable material 36 to an application site 41within the build area 13, and an exposure device 50 configured foremitting electromagnetic waves to solidify the applied material 36 toform the object 11. The application site 41 is generally defined as thearea where the material 36 contacts the deposition surface, i.e., thebuild platform 22 or the surface of the object 11. Various embodimentsof the deposition mechanism 30 are described herein, both schematicallyand with regard to specific structural embodiments. FIGS. 3 and 4schematically illustrate embodiments of the deposition mechanism 30 thatshare many features in common with the embodiment of FIG. 1, and certainaspects of the embodiments of FIGS. 3 and 4 may be described only withrespect to their differences from the embodiment of FIG. 1, for the sakeof brevity. FIGS. 8-13 and 15-18 illustrate additional embodiments ofthe manufacturing apparatus 12 and the deposition mechanism 30 thatinclude structures that may be more detailed than the schematicdepictions and may have similar or different functionality.

The carriage 32 is configured to move along the track 14 to move thedeposition mechanism 30 through the build area 13 during manufacturing.The track 14 is generally configured for guiding the carriage 32 of thedeposition mechanism 30 through the build area 13 for creation of theobject 11. The apparatus 12 may include a base frame 19 for supportingthe track 14 and other components of the apparatus 12, as shown in FIGS.8-11 and 15-19. The track 14 and the carriage 32 may have complementaryengaging structure to permit movement of the carriage 32 along the track14. For example, in the embodiments shown in FIGS. 8-11 and 15-19, thetrack 14 includes two parallel beams 15, and the carriage 32 and thetrack 14 have complementary gear surfaces 33 that allow the carriage 32to roll along the beams 15 by rotation of the gear surfaces 33 on thecarriage 32. The carriage 32 is powered for rotation of the gearsurfaces 33 in the embodiments of FIGS. 8-11 and 15-19, and mayotherwise be powered for movement in various embodiments, such as bywheels or other gear arrangements, etc. In other embodiments, the powerfor movement may be supplied by external mechanisms which may or may notbe incorporated into the track 14, such as chains, cables, belts,sprockets, pistons, etc. An example of a drive motor 39 is shown in FIG.15. The speed of the carriage 32 may be adjusted depending on theproperties of the material 36, as materials 36 with differentviscosities and/or solidification rates may benefit from faster orslower drive speeds. The carriage 32 may be configured to support othercomponents of the deposition mechanism 30, such that the othercomponents move with the carriage 32. For example, in the embodiments ofFIGS. 1, 3, and 4, the carriage 32 supports at least the applicator 40,the exposure device 50, and the material supply 34. It is understoodthat these embodiments are depicted schematically and the carriage 32may support additional components as well, including the controller 100and/or other components not pictured. The carriage 32 may be configuredfor modular connection of components as well, as described elsewhereherein. The controller 100 may be configured to control the operation,speed, elevation, and other aspects of the carriage 32 and themanufacturing process. In one embodiment, numerous parameters may bedetermined prior to the commencement of the manufacturing process and/orprior to a single pass and executed by the controller 100. Suchparameters may be manually determined, automatically determined, or acombination of the same. For example, before a pass is made the layerthickness, the build direction, the build speed, the roller directionand speed, the material-to-roller communication level (determined basedon the viscosity of the material 36), and the power output of theexposure device 50 may be determined, and the deposition mechanism 30may be located to a predetermined starting (registration) position.

In the embodiments of FIGS. 1, 3-4, 8-13, and 15-19, the applicator 40includes or is in the form of a roller 42 that is in communication orcontact with the material supply 34. In these embodiments, the roller 42is cylindrical and has a cylindrical outer surface 43 in contact withthe supply 34. In the embodiments of FIGS. 1 and 3, the roller 42 ishollow or otherwise has an inner chamber, but may alternately be a solidcylinder, e.g., in the embodiments of FIGS. 3-4. The roller 42 rotatesso that material 36 is picked up on the outer surface 43 of the roller42 and is carried to the application site 41 for manufacturing of theobject 11. The roller 42 may be powered for rotation by any of variousmechanisms, such as gears, sprockets, wheels, belts, etc. In oneembodiment, the roller 42 is configured to rotate in conjunction withthe movement of the carriage 32, i.e., such that the top of the roller42 is moving in the opposite direction to and at approximately the samespeed as the movement of the carriage 32. This is schematically shown inFIGS. 1 and 3-4 and avoids drag and/or shear on the surface of theobject 11 and the applied material 36. In another embodiment, the roller42 may be configured to rotate at a different speed, i.e., faster orslower than the translational movement speed across the depositionsurface. It is contemplated that rotating the roller 42 faster than thetranslational movement speed can improve curing of the material 36 atthe deposition surface, by increasing exposure time of the material 36at the deposition surface relative to the material 36 on the surface 43of the roller 42. The roller 42 may further be made from a material thatis permeable to the electromagnetic waves that are emitted by theexposure device 50, such that the waves can pass through the roller 42relatively unchanged. The application site 41 is generally definedbetween the outer surface 43 of the roller 42 and the depositionsurface, i.e., the build platform 22 or the surface of the object 11.The spacing between the outer surface 43 of the roller 42 and thedeposition surface may define the thickness of the material 36 that isdeposited, and the ultimate thickness of the solidified material layer38. It is understood that the material of the roller 42 may becustomized to the specific wavelength of the electromagnetic waves toensure sufficient permeability. The applicator 40 may have a differentconfiguration in another embodiment, and may carry the material 36 tothe application site 41 using a different mechanism. The applicator 40may further have a different orientation relative to the build platform22, such as shown in FIG. 25.

The use of the roller 42 in certain embodiments described herein createsa moving retention area at the apex of the roller 42, and the fixeddistance between the apex of the roller 42 and the build surface (i.e.,the build platform or the last-deposited layer 38) determines thethickness of the layer being produced. Additionally, because the roller42 is in communication with the supply 34 of the material 36, anynon-solidified material 36 is returned to the supply 34, reducing oreliminating waste.

When the applicator 40 is configured as a roller 42, the surface of thebuild platform 22 and/or the surface of the roller 42 may be selected ormodified for desired adhesion properties. It is beneficial for thesurface of the build platform 22 and/or the surface of any applied layer38 of the object 11 to have greater adhesion to the solidified material36 than the surface of the roller 42. If this does not occur, materialmay adhere to the roller 42 and solidify there, causing flaws in themanufactured object 11. In one embodiment, the roller 42 may be madefrom a low-adhesion material or treated with a coating to reduceadhesion. Likewise, the surface of the build platform 22 may be madefrom a high-adhesion material or treated with a coating to increaseadhesion. In one embodiment, the roller 42 has a lower adhesion propertywith respect to the solidified material 36 than the adhesion property ofthe bonding surface for the material 36 (i.e., the build platform 22 orthe last-deposited layer 38). The adhesive properties of the flowablematerial 36 may be different for different materials.

In the embodiments of FIGS. 1, 3-4, 8-13, and 15-19, the supply 34 isconfigured as a vat of the flowable material 36 that is in contact withthe roller 42, such that rotation of the roller 42 carries the material36 to the application site 41. In this configuration, the flowablematerial 36 should have sufficient viscosity that the roller 42 is ableto carry a continuous layer of the uncured flowable material 36 to theapplication site 41. The desired viscosity of the flowable material 36may depend on the desired build speed or rotation speed of the roller42, or on the level of the roller 42 relative to the level of thematerial 36 in the supply 34. A slower rotation speed and/or a lower vatmaterial 36 level may require higher viscosity material 36. It isunderstood that the power of the exposure device 50 may require a sloweror faster speed, as more powerful waves 53 can solidify materials (e.g.,polymerizing resins) more quickly. In another embodiment, the supply 34may be more complex, such as by including injectors or nozzles to forcethe material 36 onto the roller 42. In the embodiment of FIGS. 15-19,the supply 34 includes fluid connectors 35 that may permit removableconnection of a container of additional material 36 for refill ormaintenance of the level of the material 36 in the vat. Additionally,the supply 34 of the flowable material 36 may be configured differentlyif the configuration of the applicator 40 is changed, and the supply 34may be configured to be compatible with the design of the applicator 40,or vice-versa.

In one embodiment, shown in FIG. 27, the supply 34 may be configured tohold multiple flowable materials 36A-E to permit the depositionmechanism 30 to build multiple objects 11 out of different materials36A-E or a single object 11 out of different materials 36A-Esimultaneously. As shown in FIG. 27, the supply 34 may be configured asa vat that has partitions 37 to separate the different materials 36A-E.The partitions 37 may be adjustable to alter the ratios and boundariesof the different materials 36A-E as desired. It is understood thatdescriptions of using “different materials” as used herein may alsoenable usage of the same material with different colorings.

The exposure device 50 is generally configured for emittingelectromagnetic waves 53 to solidify the applied material 36 to form theobject 11. The wavelength and intensity of the electromagnetic waves maybe selected based on the material 36 to be solidified and the speed ormechanism of solidification. For example, when a light-curable resin isused as the material 36, the exposure device 50 may be configured toemit light (visible, IR, UV, etc.) that is an appropriate wavelength forcuring/polymerizing the resin to form a solid material layer 38. Asanother example, if a sintering process is used to solidify the flowablematerial 36, the waves 53 emitted by the exposure device 50 may havesufficient power to sinter the material 36 to form a solid materiallayer 38. The exposure device 50 may also include various components andstructures to direct the emitted waves toward an exposure site 51 withinthe build area 13, where the material 36 is exposed to the waves at theexposure site 51. The waves may be directed so that the exposure site 51is located approximately at the application site 41 in one embodiment,or so that the exposure site 51 is offset from the application site 41(ahead or behind the application site 41 in the direction of travel) inanother embodiment. FIGS. 1 and 3 illustrate (with solid lines) thewaves 53 being directed to an exposure site 51 approximately at theapplication site 41, and further illustrate (with broken lines) thewaves 53 alternately being directed to an exposure site 51 offset behindor ahead of the application site 41. FIG. 4 illustrates the waves 53being directed to an exposure site 51 offset behind the application site41.

In general, the exposure device 50 is configured such that wavesgenerated by the exposure device exit through outlets 54 and aredirected toward specific areas of the exposure site 51 to permitselective solidification of the material 36 at the selected areas of theexposure site 51 as the deposition mechanism 30 passes. In oneembodiment, the exposure device 50 is part of an exposure assembly 60that includes components designed to direct and/or focus the waves 53toward the exposure site 51. The outlets 54 may be arranged in an array55, and specific outlets 54 along the array 55 may be selectivelyactivated to selectively solidify portions of the material 36, as shownin FIGS. 5A and 5B. FIGS. 5A and 5B illustrate the active outlets 56 asbeing darkened, and the inactive outlets 57 as being light. As seen inFIGS. 5A and 5B, the active outlets 56 and inactive outlets 57 arechanged when the roller 42 reaches a point where the shape or contour ofthe object 11 changes. The selective activation and deactivation of theoutlets 54 may be controlled by the controller 100, as described herein.The array 55 in FIGS. 5A and 5B is illustrated as a single horizontalrow of outlets 54. In other embodiments, the array 55 may be arrangeddifferently, such as in multiple, offset horizontal rows. The use ofmultiple rows in the array 55 can permit closer lateral spacing betweenthe outlets 54 than the use of a single row. The array 55 in FIG. 14 maysimilarly be configured and arranged according to any of theseembodiments.

As described above, the waves 53 may penetrate the roller 42 on theirpath to the exposure site 51. In the embodiment of FIG. 1, the outlets54 are located inside the roller 42 and the emitted waves 53 penetratethe surface of the roller 42 once on their paths to the exposure site51. In the embodiment of FIG. 1, the exposure device 50 itself may belocated within the roller 42, or the exposure device 50 may be locatedoutside the roller 42, with the outlets 54 positioned within the roller,as in the embodiment of FIGS. 8-13. In the embodiment of FIG. 3, theoutlets 54 are located below the roller 42 and the emitted waves 53penetrate entirely through the roller 42 in their paths to the exposuresite 51. The embodiment of FIGS. 15-18 is similarly configured. In thisconfiguration, the deposition mechanism 30 may include a window 44configured to permit the waves 53 to pass through the wall of the supplyvat 34, as shown in FIGS. 16-17. Additional structures such assqueegees, gaskets, or other sealing structures may be used to resistresin ingress between the roller 42 and the window 44. In the embodimentof FIG. 4, the outlets 54 are positioned and directed to an exposuresite 51 located immediately behind the application site 41, and thewaves 53 do not need to pass through the roller 42 in this embodiment.It is understood that the waves 53 in the embodiment of FIG. 4 may bedirected to pass through a portion of the roller 42 if so desired.

In one embodiment, the exposure device 50 is a projector, such as aDigital Light Processing (DLP) projector, as the source of the waves 53,and the exposure assembly 60 may also use optical fibers 61 to directthe waves 53 to the exposure site 51, as shown in FIGS. 8-13. In thisembodiment, the projector 50 is configured such that the light emittedby the projector 50 enters the entrance ends 62 of the optical fibers61, travels down the optical fibers 61, and exits through the exit ends63 of the optical fibers 61, directed at the exposure site 51. Theoutlets 54 in this embodiment are formed by the exit ends 63 of theoptical fibers 61, and may be located inside the roller 42 and arrangedas an array 55 inside the roller, as shown in FIGS. 1, 5A-B, and 8-12.In such an embodiment, the optical fibers 61 may extend into the roller42 from one or both ends of the cylinder, and appropriate sealing andbracing components may be used around the optical fibers 61 in thiscase. For example, in the embodiment of FIGS. 8-12, the exit ends 63 ofthe optical fibers 61 may be gathered and held in place by a casing orsimilar structure 67 (see FIGS. 5A-5B). The exposure assembly 60 mayfurther use a focusing mechanism 66 to focus the light waves 53 afterthey exit the exit ends 63 of the optical fibers 61, as illustrated inFIG. 13. In one embodiment, the focusing mechanism 66 includes amicro-lens array 64 between the exit ends 63 of the optical fibers 61and the object 11, such as a Selfoc Lens Array (SLA) lens, that focusesthe waves 53 and avoids diffraction on the path to the exposure site 51.FIGS. 8-12 illustrate a micro-lens array 64 being held in place withinthe roller 42 by braces 65. In other embodiments, various other lenses,mirrors, and other focusing equipment may be used. It is understood thatsuch a focusing mechanism 66 may be used in other embodiments describedherein, such as the embodiments of FIGS. 3, 4, 15-18, and 25. It is alsounderstood that the use of the optical fibers 61 permit the wave sourceof the exposure device 50 to be positioned remotely from the applicator40, e.g., elsewhere on the deposition mechanism 30 or even away from thedeposition mechanism 30 in some embodiments. In this configuration heatproduced by the exposure device is not transmitted to the applicator orthe material 36, which can avoid undesired solidification, change ofproperties of the material 36, or thermal distortion of the applicator40. This configuration also permits an exposure device 50 to use a muchlarger and/or more powerful wave source (e.g., high power LED's or ahigh-power DLP projector) without regard for physical limitations, e.g.,fitting inside the roller 42.

The exposure assembly 60 in the embodiment of FIGS. 8-13 uses acollector 70 engaged with the entrance ends 62 of the optical fibers 61to fix the entrance ends 62 in position with respect to the exposuredevice 50, such that the waves 53 enter the entrance ends 62 of theoptical fibers 61 at the collector 70. One embodiment of the collector70 is illustrated in FIG. 12 and schematically in FIG. 13. The collector70 includes a frame 71 that engages the entrance ends 62 of the opticalfibers 61 and holds the entrance ends 62 within a chamber or passage 72,with a window 73 (which may be configured as a lens in one embodiment)positioned at the end of the passage 72. Waves 53 exiting the exposuredevice 50 pass through the window 73 to enter the entrance ends 62 ofthe optical fibers 61. A lens 66A may be positioned between the exposuredevice 50 and the window 73 to focus the waves 53 at this stage. Theframe 71 is held firmly in place relative to the exposure device 50, sothat the entrance ends 62 of the optical fibers 61 do not move relativeto the exposure device 50. This fixed relative positioning permits theexposure device 50 to selectively activate and deactivate the outlets 54by use of pixel mapping. In other words, the entrance end 62 of eachoptical fiber 61 is mapped to one or more specified pixels of theexposure device 50, such that activating the specified pixel(s) causeswaves 53 emitted by the specified pixel(s) to travel down the opticalfiber 61, thereby activating the outlet 54 associated with that opticalfiber 61. The pixel mapping also incorporates mapping of the specificarea of the exposure site 51 toward which the outlet 54 of each opticalfiber 61 is directed. In one embodiment, where a DLP projector is usedas the exposure device 50, each optical fiber 61 is mapped to aplurality of pixels (potentially hundreds or more) of the DLP projector.In such a configuration, loss or inactivation of multiple pixels canoccur without affecting the ability of the optical fiber 61 to maintainsufficient functionality and power for operation. The use of thecollector 70 and optical fibers 61 as described herein achieves theconversion of a two-dimensional projection into a roughlyone-dimensional (linear) exposure. This mapping may be stored incomputer memory and executed by a computer processor, such as by thecontroller 100.

In another embodiment, the exposure device 50 is in the form of an array55 of LEDs 59 that function as the sources of the waves 53, as shown inFIG. 14. The LEDs 59 may be designed to emit waves 53 of the properwavelength and intensity for solidifying the material 36. The array 55of LEDs 59 can be positioned within the roller 42 as shown in FIG. 14,or outside the roller 42 as described herein, and may use a focusingmechanism 66 as also described herein. In either case, a micro-lensarray 64 at the outlets 54 as described above may assist in focusing thewaves 53. Each of the LEDs 59 in this embodiment constitutes a separateoutlet 54 that is directed at a specific area of the exposure site 51,and the LEDs 59 can be selectively activated and deactivated to exposethat specific area of the exposure site 51 to the waves 53. Theactivated LEDs 59 constitute active outlets 56 and are shown as beingdarkened in FIG. 14, and the inactive LEDs 59 constitute inactiveoutlets 57 that are shown as being light. As seen in FIG. 14, thematerial 36 aligned with the active outlets 56 is being solidified toform a layer 38. The LEDs 59 may be mapped to the specific areas of theexposure site 51 toward which they are directed, and this mapping may bestored in computer memory and executed by a computer processor, such asby the controller 100. If the LEDs 59 are positioned outside the roller42, a plurality of optical fibers 61 may be used in conjunction with theLEDs 59, forming the outlets 54. FIG. 66 schematically illustrates oneembodiment of this configuration, with an array 55 of LEDs 59 positionedseparately from the applicator 40, where the optical fibers 61 havetheir entrance ends 62 fixed in position relative to the LEDs 59 so thatwaves 53 from the LEDs 59 enter the optical fibers 61 and are emitted atthe exit ends 63, forming outlets 56 as described above. The outlets 56may be configured in the same manner as shown and described herein withrespect to the embodiment of FIGS. 1-13 and other embodiments, includingthe use of a focusing mechanism 66 and mechanisms for adjusting thedirection of the waves 53 forward or rearward in the direction of travelof the deposition mechanism 30, which are not shown in FIG. 66. Theentrance ends 62 of the optical fibers 61 may be fixed in positionrelative to the LEDs 59 using various fixing and bundling structures asappropriate for the size and arrangement of the LED array 55, and it isunderstood that the LED array 55 may not be linearly arranged in someconfigurations. In one embodiment, no lens or other focusing structuremay be necessary between the LEDs 59 and the entrance ends 62 of theoptical fibers 61. Each LED 59 may be mapped to an individual opticalfiber 61 in the embodiment shown in FIG. 66, although in otherembodiments, multiple optical fibers 61 may be mapped to each LED 59.This configuration permits the use of an array of LEDs that is largerthan can be incorporated inside the applicator 40. In furtherembodiments, a different type of exposure device 50 may be used, and thedeposition mechanism 60 may include components configured to direct thewaves 53 from the exposure device to the proper areas of the exposuresite 51. For example, in the embodiment of FIGS. 15-19, the exposuredevice 50 is in the form of a laser, and a focusing mechanism 66including lenses and/or mirrors is used to focus the beam. The focusingmechanism 66 in FIGS. 16-17 includes one or more lenses 66A and one ormore mirrors 66B. In still further embodiments, the exposure device 50may be in the form of an LCD source or a high-speed positionablemechanical shutter system.

During operation of the apparatus 12, the spacing between the applicator40 and the deposition surface must be changed for each new layer 38 ofthe object 11 that is deposited. The applicator 40 in the embodiments ofFIGS. 1, 3-4, 8-11, and 15-19 is oriented so that the roller 42 ispositioned vertically below the deposition surface and forms the layer38 vertically above the roller 42. In this embodiment, relative verticaltranslation (i.e., parallel to the layer-by-layer build direction)occurs between the applicator 40 and the deposition surface duringmanufacturing of successive layers 38. This vertical translation isillustrated, e.g., in FIGS. 6A and 6B, which illustrate the depositionmechanism 30 making a first pass (FIG. 6A) from left to right to deposita first layer 38 and a second pass (FIG. 6B) from right to left todeposit a second layer 38, where the vertical translation between thefirst and second passes is shown in phantom lines. This relative changein positioning can be accomplished using one or more different methodsand mechanisms or combinations thereof. In the embodiments of FIGS. 8-11and 15-19, this vertical translation can be accomplished by changing theelevation of the build platform 22, using a vertical positioningmechanism 23 as described herein. In another embodiment, this verticaltranslation can instead be accomplished by changing the elevation of thetrack 14, which may be accomplished using similar vertical positioningmechanisms 23 as described herein. In a further embodiment, thedeposition mechanism 30 may include a mechanism for changing thevertical position of the applicator 40 relative to the build platform22, such as by raising or lowering the applicator 40 and/or the entirechassis 32. For example, in the embodiment of FIGS. 20A-B, thedeposition mechanisms 30 each are capable of vertical translationrelative to the track 14 through a limited range of motion by raising orlowering the carriage 32 relative to the track 14. The verticaltranslation may be accomplished by switching the carriage 32 betweenpre-set vertical positions, such as by vertically moving the drivestructure that engages the track 14 with respect to the roller 42. Theprimary vertical translation of the build platform 22 relative to theapplicator 40 in this embodiment is accomplished by movement of thebuild platform 22 as described herein, and the vertical positioningrange of the deposition mechanism 30 permits multiple depositionmechanisms 30 to make passes through the build area 13 without adjustingthe position of the build platform 22, which is more time-consuming. Theoperation of these embodiments are described in further detail herein.

The deposition mechanism 30 may include further additional components toprovide additional functionality in producing a high-quality object 11.It is understood that any of the example embodiments herein may includeany combination of these additional components, even if not specificallyillustrated herein. For example, the deposition mechanism 30 may includeone or more secondary exposure devices 80, configured to trail theapplicator 40 in the direction of movement, as shown in FIG. 7. Thesecondary exposure device 80 emits additional electromagnetic waves 53to further solidify the material, which waves 53 may have the same ordifferent wavelength and intensity as the waves 53 from the exposuredevice 50. In one embodiment, the secondary exposure device 80 does notneed to be precisely focused, as it is acceptable for the entire surfaceof the object 11 to be irradiated. In this configuration, the waves 53from the exposure device 50 may be configured to only solidify thematerial 36 enough to form a stable layer 38 (known as a “green state”),and the secondary exposure device 80 then further solidifies the layer38 to the desired final degree of solidification. This presents asignificant efficiency advantage over existing processes, where objects11 are typically produced in the green state and require a subsequentseparate irradiation step for full curing. In one embodiment, the powerlevels of the exposure device 50 and the secondary exposure device 80may be set so that each exposure device 50, 80 partially solidifies thematerial 36 and the combined exposure is sufficient to completelysolidify the material 36. This setting avoids overexposure of thematerial 36, which could cause aesthetic and/or mechanical damage. Theembodiment of FIGS. 15-19 includes two secondary exposure devices 80, topermit secondary exposure of the layer 38 while the carriage 32 istraveling in two opposite directions without making a 180° turn. Theleading secondary exposure device 80 may be deactivated for each pass ofthe carriage 32, with the trailing secondary exposure device 80 beingactive, or both secondary exposure devices 80 may be active. Components80A of the secondary exposure device 80 are illustrated in FIG. 16. Thecontroller 100 may control activation of the secondary exposuredevice(s) 80.

As another example, the deposition mechanism 30 may include one or morematerial removal and/or relocation mechanisms configured to remove orrelocate excess and/or unsolidified material, such as one or moresqueegees 81 or one or more contactless vacuum squeegees 82. Forexample, the embodiment in FIGS. 15-19 includes two squeegees 81positioned on alternate sides of the roller 42, which wipe the surfaceof the layer 38 to remove excess and/or unsolidified material 36 afterthe solidification process. In one embodiment, the squeegees 81 may beconfigured to be raised and lowered, so that only the trailing squeegee81 engages the surface of the object 11, which operation may becontrolled by the controller 100. As another example, the embodiment inFIGS. 15-19 also includes two vacuum squeegees 82 positioned onalternate sides of the roller 42, which remove or relocate excess and/orunsolidified material 36 after the solidification process throughapplication of vacuum airflow through blowing or suction. Components82A-B of the vacuum squeegees 82 are shown in FIG. 16. In oneembodiment, the vacuum squeegees 82 may be configured to be activatedand deactivated, so that only the trailing vacuum squeegees 82 affectsthe surface of the object 11, which operation may be controlled by thecontroller 100. In one embodiment, the vacuum squeegees 82 can relocateremaining flowable material 36 located on vertical surfaces of theobject 11 to adjacent horizontal surfaces of the applied layer 38, wherethe material 36 can either be removed and reclaimed into the supply 34by the mechanical squeegees 81 or solidified to become part of theapplied layer 38, e.g., by a secondary exposure device 80. Moving anyremaining material 36 to the surface of the object 11 to be solidifiedhas the added benefits of creating additional edge volume and anirregular surface at the edges of the layer, which can aid in retentionand bonding of the next applied layer 38. In one embodiment, the vacuumsqueegees 82 may not be activated until one or more foundation layers ofthe object 11 are completed. The vacuum squeegees 82 may alternately beconfigured to completely remove excess and/or unsolidified material inanother embodiment. The embodiment in FIGS. 8-11 includes squeegees 81and vacuum squeegees 82 configured similarly to those in the embodimentof FIGS. 15-19.

FIG. 65 illustrates relocation and subsequent solidification ofunsolidified flowable material 36 using the vacuum squeegee 82 asdescribed herein that can occur according to one embodiment. In FIG. 65,Step A depicts the unsolidified material 36 remaining around the edgesof the last solidified layer 38A that was solidified by the exposuredevice 50, which is stacked onto previous layers 38B that werepreviously solidified. The shading in the layers 38A-B in FIG. 65illustrate different degrees of solidification/curing of the material36. Step B in FIG. 65 depicts the relocation of the unsolidifiedmaterial 36 by the vacuum squeegee 82 as described herein. Theunsolidified material 36 has been relocated from the vertical surfaces93 of the layer 38A to the horizontal surface 94 of the layer 38A, andremains near the edges of the horizontal surface 94. Step C in FIG. 65depicts the solidification of the material 36 by a secondary exposuredevice 80 as described herein, to form solidified material 38C. Thesolidified material 38C in this configuration forms uneven portions nearthe edges of the previous layer 38A. Step D in FIG. 65 depicts theobject 11 after application and solidification of the following layer38D, for which binding to the previous layer 38A is enhanced by the edgeportions of the solidified material 38C. Additional unsolidifiedmaterial 36 is illustrated in Step D, and it is understood that theprocess may then return to Step B in a cycle until the build iscompleted.

Further additional components may be included in other embodiments. Inone embodiment, one or more additional components 83 may be modularlyconnectable to the carriage 32 and to each other to provide the desiredfunctionality, as shown in FIG. 19. Removable connections such asfasteners, clamps, interlocking structures (e.g., tabs/slots), or otherstructures may be used to effect these modular connections. Asillustrated in FIG. 19, each of the additional components 83 isconnectable to the carriage 32 and connectable to the outer side of eachother additional component 83 in order to provide a fully modular andcustomizable structure. Such additional components 83 may include one ormore secondary exposure devices 80, squeegees 81, or vacuum squeegees 82as described herein. Such additional components 83 may also includeother functional components, such as a solvent or liquid washingapparatus, mechanical wipers/cleaners, a color applicator, or anapparatus for additional material deposition. A color applicator used inthis configuration can allow coloring to be applied on a layer-by-layerbasis, giving the final object 11 a coloring that penetrates internallythrough the thickness of the object 11, instead of simply a surfacecoating. An apparatus for additional material deposition may include anapparatus for deposition of conductive materials or traces within thebody of the object 11, providing conductivity and/or circuitfunctionality to the object 11.

The apparatus 12 may be configured to use multiple deposition mechanisms30 and/or multiple applicators 40 to pass through the build area 13 insequence, such as illustrated in FIGS. 20-23. The multiple depositionmechanisms 30 in FIGS. 20-23 are illustrated as being connected to thesame track 14, but multiple tracks 14 may be used in another embodiment.In one embodiment, as illustrated in FIGS. 20A-B, multiple depositionmechanisms 30 may be configured to pass through the build area 13sequentially, with each deposition mechanism 30 having the applicator 40at different vertical positions. The different applicator 40 positionsare indicated by phantom lines in FIGS. 20A-B, and each successivedeposition mechanism 30 is spaced lower than the preceding depositionmechanism 30. This configuration may be accomplished using verticalpositioning structures described elsewhere herein. It is understood thatthe difference in vertical positioning among the multiple depositionmechanisms 30 may be substantially the same as the desired thickness ofeach applied layer 38. As shown in FIG. 20A, multiple depositionmechanisms 30 passing through the build area 13 each deposit a layer 38,one on top of the next, in a single pass that does not requirere-positioning of the support assembly 20. This configuration results inmultiplicative efficiency and time savings, as each pass in FIG. 20Adeposits 3× as many layers as a single pass with a single depositionmechanism 30. Further, the multiple deposition mechanisms 30 may beconfigured to adjust their heights in the reverse order to enable a passin the opposite direction to deposit three additional layers 38, afterrepositioning of the build platform 22, as shown in FIG. 20B. In anotherembodiment, the support assembly 20 may be configured for rapidlyadjusting the positioning of the build platform 22 between eachdeposition mechanism 30 passing, to enable multiple passes, as shown inFIG. 22. In a further embodiment, the track 14 may be arranged in a loopor carousel configuration to enable passes by one or more depositionmechanisms 30 at the same relative build platform 22 height, withoutreversing the direction of the deposition mechanism(s) 30. This canremove the necessity for re-adjusting the relative heights of thedeposition mechanisms 30 relative to each other, and only adjustment ofthe build platform 22 relative to the track 14 is necessary. This canalso remove the need for duplicative components such as secondaryexposure devices 80, squeegees 81, vacuum squeegees 82, etc., to permitopposite directional passes. The loop of the track 14 may be horizontal,vertical, or a more complex configuration. When multiple depositionmechanisms 30 are used, all deposition mechanisms 30 may use the samematerial 36, or different deposition mechanism 30 may be configured toapply different materials 36. Due to differences in properties ofdifferent materials 36, the deposition mechanism 30 may need to pass atdifferent speeds. A self-propelled carriage 32 as described hereinpermits this operation. Still further, the track 14 may include acomplex structure (not shown) with rest areas for unused depositionmechanisms and track-switching mechanisms, to permit switching betweendeposition mechanisms 30 as desired.

In another embodiment, multiple deposition mechanisms 30 may beconfigured as illustrated in FIGS. 20A-B to pass through the build area13 sequentially, with the deposition mechanisms 30 having theapplicators 40 at the same vertical positions. This can be used to builddifferent portions of the same layer of an object 11, and in particular,the deposition mechanisms 30 can be configured to deposit differentmaterials 36 in the layer. For example, different deposition mechanisms30 can produce portions with different colors, or one depositionmechanisms 30 may produce the body of the object 11 while anotherproduces the support structure to be later removed.

In another embodiment, shown in FIG. 21, a single deposition mechanism30 may include multiple applicators 40 positioned at different heightsto define separate application sites 41, with sufficient outlets 54 forthe waves 53 emitted by one or more exposure devices 50 to define aseparate exposure site 51 for each applicator 40. The multipleapplicators 40 may be configured with a single supply 34 of the flowablematerial 36 or multiple supplies 34 of one or more flowable materials36, and it is understood that other components may be duplicated ifdesired. The rollers 42 in FIG. 21 may be vertically adjustable relativeto each other in one embodiment.

In other embodiments, shown in FIGS. 24A-B, a single or multipledeposition mechanisms 30 may be configured to build multiple objects 11in a single pass, such as by using multiple build platforms 22 ormultiple objects 11 built on the same build platform 22, with eachseparate object 11 having a separate build area 13 through which thetrack 14 passes. As shown in FIG. 24A, multiple deposition mechanisms 30may apply multiple consecutive layers 38 to multiple objects 11 in asingle pass. As shown in FIG. 24B, multiple deposition mechanisms 30 mayapply different portions of the same layer 38 to each of multipleobjects 11 in a single pass. This configuration may be particularlyuseful for a part where multiple materials need to be deposited in thesame layer, such as for a multi-material object 11 or an object 11 thatincludes support structure being manufactured along with the object 11that will be later removed. It is understood that the height(s) of thebuild platform(s) 22 relative to the applicator(s) 40 may be adjustedbetween passes as described herein. Additionally, the use of multipledeposition mechanisms 30 and/or multiple applicators 40 as shown inFIGS. 20-23 with an embodiment as shown in FIG. 24 may enable duallymultiplicative efficiency and time savings. Further, the use of multipledeposition mechanisms 30 and/or multiple applicators 40 as shown inFIGS. 20-23 in combination with an embodiment as shown in FIG. 24A or24B may enable different parts of multiple identical objects 11 to besimultaneously manufactured in a single pass of each depositionmechanism 30. For example, a first deposition mechanism 30 may be loadedwith a first material 36 for manufacturing a first part of an object 11,and a second deposition mechanism 30 may be loaded with a secondmaterial 36 for manufacturing a second part of the object 11, and eachof these deposition mechanisms 30 can be configured make a single passdepositing a layer 38 (or partial layer) of the desired material 36 inthe same location on a plurality of identical objects 11 sequentially asshown in FIG. 24A-B. It is understood that different depositionmechanisms 30 may also include different exposure devices 50 ifdifferent materials 36 are used.

FIG. 28 illustrates an additional embodiment of a system 10 formanufacturing one or more objects 11 utilizing an apparatus 12 anddeposition mechanisms 30 according to embodiments described herein. Inparticular, the embodiment of FIG. 28 may be configured for producing anumber of objects 11 in sequence, similar to the embodiment of FIG. 24.Each deposition mechanism 30 in the embodiment of FIG. 28 may beconfigured as an autonomous unit 90 with an individual sub-controller,where all of the sub-controllers for all of the units 90 are integratedwith the controller 100, such that the controller 100 controls thesub-controllers and thereby controls all of the units 90. Each unit 90may further include one or more positioning systems, including a localpositioning system and/or a global positioning system (GPS). Each unit90 may further include a deposition mechanism 30 and a drive mechanism91 configured for moving the unit 90 around during manufacturing. Asshown in FIG. 28, the units 90 are all connected to a carousel 92 thatmoves the units 90 around to a plurality of stations. The stations mayeach be configured for a specialized purpose. For example, some stationsmay be manufacturing stations where the unit 90 makes a pass through oneor more build areas 13 for manufacturing one or more objects 11 on oneor more build platforms 22. Such stations may also include roboticcomponents, such as robotic arms that hold a build platform 22 in theproper location for building by the units 90. Other stations may bemaintenance stations, such as stations configured for refilling thesupply 34 the unit 90. The carousel 92 may have one or more tracks 14 asdescribed herein for guiding movement of the units 90 during building.The drive mechanism 91 may be multi-functional, such that the units 90are autonomously powered and capable of engaging and disengaging fromthe track 14 and moving separately from the track 14 when not in thebuilding process, such as for visiting refilling or maintenancestations. In the configuration illustrated in FIG. 28, each unit 90 maybe loaded with a different material 36 for manufacturing different partsof a single object 11 or different objects, as described above withrespect to FIG. 24. This configuration therefore provides the abilityfor rapid manufacturing of a series of objects 11, either identicalobjects 11 or different objects 11.

FIG. 29 illustrates an additional embodiment of a system 10 formanufacturing one or more objects 11 utilizing an apparatus 12 and adeposition mechanism 30 with an applicator 40 that is different from theroller 42 described herein. In the embodiment of FIG. 29, the applicator40 includes a moveable film 84 that is in communication with the supply34 of the flowable material 36 and carries the flowable material 36 tothe application site 41 by lateral movement to form a layer 38 of theobject 11. The deposition mechanism 30 in FIG. 29 has a static surface85 that defines the location of the application site 41 and thethickness of the applied layer 38 as described above, and the film 84carries the material 36 to the application site 41 by moving over thestatic surface 85. The static surface 85 is formed by a cylinder in FIG.29, but may be formed by a ridge or other structure in otherembodiments. For example, FIG. 30 illustrates an embodiment of a system10 as shown in FIG. 29 with a flattened static surface 85 that is formedby a trapezoidal structure. An oval, obround, or other structure with anelongated or flattened surface may be used in other embodiments. Thedeposition mechanism in FIG. 29 also has two rolls 86 on opposite sidesof the application site 41, which serve as take-up or supply stations,depending on the direction of movement. For example, in FIG. 29, thedeposition mechanism is moving from left to right as indicated, and thefilm 84 is moving from right to left, with the left hand roll 86 servingas a take-up station and the right-hand roll 86 serving as the supplystation. This will be reversed when moving from right to left. Othercomponents are also included such as guide rollers 87 or other guidesfor the film 84, squeegees 81 or other material removal devices toremove the flowable material 36 from the film 84 before reaching atake-up roller 86, and a cleaning station 88 for cleaning the film 84stored on the rolls 86. While the carriage 32 is not shown in FIG. 29,it is understood that all of these components may be mounted on acarriage 32 as described herein. As shown in FIG. 29, the exposuredevice 50, or at least the outlets 54 thereof, may be located beneaththe static surface 85 and within the cylinder that defines the staticsurface 85, although any configuration and positioning of the exposuredevice 50 and the outlets 54 thereof described herein can be used inconnection with this embodiment. In the illustrated configuration, thewaves 53 from the exposure device 50 pass through both the staticsurface 85 and the film 84 on the path to the exposure site 51. In anadditional embodiment, the static surface 85 may have a gap that permitsthe waves 53 to pass to the exposure site 51 without passing through thestatic surface 85. In a further embodiment, the static surface 85 mayhave an array 55 of outlets 54 mounted within such a gap, which mayplace the outlets 54 in such close proximity to the exposure site 51that no lenses or other focusing equipment may be necessary.

FIG. 25 illustrates an alternate embodiment of the system 10 andapparatus 12 that uses a traditional vat supply 34 of the flowablematerial 36, with the deposition mechanism 30 positioned above the buildplatform 22. The deposition mechanism 30 in this embodiment generallyincludes a carriage 32 that is configured for movement along a track 14,with a roller 42 and an exposure device 50 that emits waves 53 that passthrough the roller 42 on their path to the exposure site 51. In thisembodiment, the roller 42 does not act as an applicator as in theembodiments of FIGS. 1 and 3-4, but does define the thickness of theapplied layer 38 of the material 36, similarly to the such previousembodiments. As such, the roller 42 in this embodiment acts as alayer-defining mechanism, and differently configured structures may beused for this purpose in other embodiments, such as a block shape thatslides along or through the material 36. The build platform 22 in FIG.25 and associated structures may be configured to have a removablestructure as described elsewhere herein. Additionally, the depositionmechanism 30 and/or the build platform 22 may have adjustment mechanisms(not shown) for relative vertical positional adjustment of the buildplatform 22 and the roller surface 42. The adjustment mechanism mayinclude structures described herein and/or structures used in existingvat-based rapid prototyping technologies, such as moving the buildplatform 22 gradually deeper into the vat supply 34. This embodimentenables the object 11 to be manufactured below the surface of theflowable material 36 if so desired, with a controllable layer 38thickness. However, this embodiment does not provide some of theadvantages of the other embodiments described herein, such aseliminating the requirement to maintain a large vat supply 34 of theflowable material 36. It is understood that the embodiment of FIG. 25may include additional structure, components, and features describedherein. For example, the system 10 illustrated in FIG. 25 also includesa controller 100 configured for controlling and/or monitoring componentsof the apparatus 12 as described herein. As another example, theexposure device 50, or at least the outlets 54 thereof, are illustratedin FIG. 25 as being located inside the roller 42, but the exposuredevice 50 may be configured similar to that in FIG. 3 to projectcompletely through the roller 42 in another embodiment.

FIGS. 31-46 illustrate another embodiment of a system 10 that includes amanufacturing apparatus 12 that may be connected to a computercontroller 100 in communication with one or more components of theapparatus 12 and configured for controlling operation of the apparatus12 and/or the components thereof to manufacture an object 11. Theapparatus 12 of FIGS. 31-46 includes a support assembly 20 forsupporting the object 11 within a build area 13 during manufacturing, atrack 14 extending through the build area 13, and a material depositionmechanism 30 mounted on the track 14 and configured for producing theobject 11 within the build area 13 through layer-by-layer application ofa material. Many components of the system 10 and apparatus 12 of FIGS.31-46 are similar in structure and operation to other componentsdescribed herein with respect to other embodiments, and such componentsmay not be described again in detail with respect to the embodiment ofFIGS. 31-46. It is understood that similar reference numbers may be usedto indicate such similar components. The deposition mechanisms 30 inFIGS. 31-46 are configured for operation as autonomous units 90 asdescribed herein, and each autonomous unit 90 may have onboard aprocessor 2604, a memory 2612, and/or other computer componentsnecessary for executing computer-executable instructions to automate theautonomous unit 90 and/or communicate with the computer controller 100.

The support assembly 20 in FIGS. 31-46 includes a base frame 19 forsupporting some or all of the track 14, the build platform 22, and othercomponents of the apparatus 12. In the embodiment of FIGS. 31-46, thetrack 14 is not supported by the base frame 19 and is fixed separatelyto the floor, but the track 14 may be connected to and supported by thebase frame 19 in another embodiment. The track 14 includes two parallelbeams or rails 15 and at least one bus bar 101 configured for supplyingpower to the deposition mechanism 30. The bus bar(s) 101 may be part ofone or both of the rails 15 in one embodiment. Additionally, thesubstantial entirety of one or both rails 15 may act as the bus bar(s)101 in one embodiment. One or more bus bars 101 may be provided separatefrom the rails 15 in another embodiment. The track 14 may not containany bus bar 101 in another embodiment, and the deposition mechanism 30(i.e., the autonomous unit 90) may be self-powered for movement andoperation, such as by an internal battery. It is understood that thetrack 14, the build platform 22, the support assembly 20, and othercomponents may be constructed in any desired size, including lengths andwidths that are significantly larger than those illustrated in FIGS.31-42.

The deposition mechanism 30 in the embodiment of FIGS. 31-46 includes acarriage 32 engaged with the track 14 and configured for movement alongthe track 14 and through the build area 13, a supply 34 of a flowablematerial 36 mounted on or otherwise operably connected to the carriage32, an applicator 40 in communication with the supply 34 of the flowablematerial 36 and configured to apply the flowable material 36 to anapplication site 41 within the build area 13, and an exposure device 50configured for emitting electromagnetic waves to solidify the appliedmaterial 36 to form the object 11. The supply 34 of the flowablematerial 36, the applicator 40, and the exposure assembly 60 in theembodiment of FIGS. 31-46 are similar or identical in function andstructure to the same components in the embodiment of FIGS. 8-13 andneed not be re-described herein in detail. The supply 34 of the flowablematerial 36 and the applicator 40 in the embodiment of FIGS. 31-46 areconnected so as to form an integrated application module 110, alsoreferred to as a resin application module 110, which is removable fromthe carriage 32 and replaceable with a second application module 110.FIGS. 44-46 illustrate an example of such an application module 110 andthe process of removing and replacing the application module 110. FIG.43 illustrates a portion of the application module 110, including theroller 42 and the structures defining the supply 34. As seen in FIGS.43-46, the supply 34 is provided in the form of a vat or reservoir withthe roller 42 at least partially disposed within the reservoir to be incommunication with the flowable resin 36, and the supply 34 can beremoved without draining the resin 36 if so desired. The applicator 40in this embodiment is in the form of an elongated roller 42, and one orboth of the ends of the roller 42 is connected to the side walls 111 ofthe vat 34. The optical fibers 61 pass through an opening 112 extendingthrough one of the side walls 111 and the end of the roller 42 to passinto the interior of the roller 42 to form the array 55 of outlets 54within the roller 42. The braces 65 and associated supporting structure113 holding the fibers 61, the micro-lens array 64 and other componentsof the exposure device 50 remain in place when the application module110 is removed. It is understood that a side panel 114 of the carriage32 is removed in this embodiment in order for the application module 110to be removed, as shown in FIG. 44. The removable side panel 114 in theembodiment of FIGS. 31-46 is on the opposite side of the carriage as thedrive assembly 115 that drives rotation of the roller 42. In oneembodiment, either or both side panels 114 of the deposition mechanism30 may include a resin tank connected to the supply 34 to replace usedmaterial 36 and/or keep the level of the material 36 constant. Thedeposition mechanism in FIGS. 8-13 may also include a removableapplication module 110 as described herein, such as shown in FIG. 47.

After the application module 110 is removed as shown in FIGS. 44-45, thesame or a different application module 110 may be replaced in the samemanner, as shown in FIG. 46. In one embodiment, a first applicationmodule 110 can be removed and replaced with a second application module110 that has a different characteristic. For example, the secondapplication module 110 may have a differently configured applicator 40or may have a different flowable material 36, enabling switching offlowable materials 36 without draining, cleaning, and refilling thesupply 34. As another example, the application module 110 may be removedfor repair or refill and replaced with a backup application module 110to avoid downtime. In other embodiments, either the supply 34 or theapplicator 40 may be independently removable and replaceable using asimilar configuration. Other removable configurations may be used inother embodiments.

The support assembly 20 further includes a mechanism 102 for moving thebuild platform 22 between a build position and a tending position, wherethe build platform 22 faces toward the track 14 for production of anobject 11 in the build position, and the build platform 22 faces awayfrom the track 14 in the tending position, to permit a tending operationto be performed on the object 11. Examples of tending operations includemodifying the object 11, such as by material removal, including removalof support structure (e.g., by cutting, machining, etc.), painting,cleaning, or removing the object 11 from the build platform 22, such asif production of the object 11 is completed, or inserting or attachingfunctional or non-functional components previously manufactured by thesame or different process (also referred to as secondary objects), suchas RFID chips, magnets, added weights or structural supports, printedcircuit boards, liquid tanks, etc. Such a secondary object may beconnected in a configuration such that it is not exposed to the waves 53during continuing production of the object 11 when the build platform 22is returned to the build position. For example, the secondary object maybe inserted within an internal cavity of the partially-built object 11and/or provided with a protective casing. In one embodiment, thesecondary object(s) may be other objects 11 manufactured simultaneouslyon the same or other build platforms 22 as described herein. In theembodiment of FIGS. 31-46, the mechanism 102 moves the build platform 22between the build position and the tending position by rotation. FIGS.31-33 and 37 illustrate the build platform 22 in the build position,FIG. 34 illustrates the build platform 22 being moved from the buildposition to the tending position, and FIGS. 35 and 36 illustrate thebuild platform 22 in the tending position in this embodiment.

The mechanism 102 for moving the build platform 22 in the embodiment ofFIGS. 31-46 includes a support platform 24 that defines and/or supportsthe build platform 22 as described herein, with one or more rotatingbases 103 connected to the support platform 24 and configured forrotating to move the support platform 24. As shown in FIGS. 31-37, themechanism 102 includes two rotating bases 103 at opposed ends of thesupport platform 24 that are configured for rotating in unison about anaxis, and the support platform 24 is fixed with respect to the rotatingbases 103. The rotating bases 103 are mounted on the base frame 19 andconfigured to rotate with respect to the base frame 19. The supportplatform 24 in this embodiment is offset from the axis and parallel tothe axis such that the support platform 24 and the build platform 22orbit the axis when the rotating bases 103 rotate. This orbital actionresults in the build platform 22 both facing in a different directionand changing in height when moving between the build position and thetending position. The build platform 22 in this embodiment is higher inthe build position, in order to permit more build space in the verticaldirection, and is lower in the tending position, in order to facilitatemanual manipulation of any object(s) 11 on the build platform. Inanother embodiment, the support platform 24 may be rotationally alignedwith the axis of the rotating base(s) 103, such that the supportplatform 24 rotates rather than orbits in moving between the buildposition and the tending position. In another embodiment, the supportplatform 24 may have a different arrangement, such as a cantileverarrangement where only a single rotating base 103 is provided at one endof the support platform 24, or an arrangement where the rotating base(s)103 are not located at the ends of the support platform 24. In a furtherembodiment, a different type of movement mechanism 102 may be used.

FIGS. 62-64 illustrate another embodiment of a mechanism 102 for movingthe build platform 22 between the build position and the tendingposition. FIG. 62 illustrates the build platform 22 in the buildposition, FIG. 63 illustrates the build platform 22 being moved from thebuild position to the tending position, and FIG. 64 illustrates thebuild platform 22 in the tending position in this embodiment. In theembodiment of FIGS. 62-64, the mechanism includes one or more pivotingbases (or pivoting arms) 116 connected to the support platform 24 andconfigured for pivoting to move the support platform 24 upward anddownward. As shown in FIGS. 62-64, the mechanism 102 includes twopivoting bases 116 at opposed ends of the support platform 24 that areconfigured for pivoting in unison about a common axis, and the supportplatform 24 is configured for pivoting with respect to the pivotingbases 116. The pivoting bases 116 are pivotably mounted on the baseframe 19 and configured to pivot with respect to the base frame 19. Asshown in FIGS. 63 and 64, in moving from the build position to thetending position, the pivoting bases 116 pivot downward to lower thelevel of the build platform 22 for ease of access, and the supportplatform 24 pivots with respect to the pivoting bases 116 to cause thebuild platform 22 to face upward and/or away from the track 14.Similarly, in moving from the tending position to the build position,the pivoting bases 116 pivot upward to raise the level of the buildplatform 22, and the support platform 24 pivots with respect to thepivoting bases 116 to cause the build platform 22 to face downwardand/or toward the track 14 for use in production. In another embodiment,the support platform 24 may rotate about a central axis on the pivotingbases 116, rather than pivoting, with respect to the pivoting bases 116.The configuration in FIGS. 62-64 permits greater ability to adjust theheight of the build platform 22 in the tending position, and alsoprovides more clearance room for an autonomous unit 90 to engage withthe track 14 (such as without lowering the applicator 40 as describedherein).

FIGS. 34-37 and 62-64 illustrate the build platform 22 and the supportplatform 24 being rotated 180° between the build position and thetending position, such that the build platform 22 faces downward in thebuild position and upward in the tending position. In other embodiments,the build platform 22 and the support platform 24 may be orienteddifferently in the tending position, such as rotating 90° or 135° fromthe build position. For example, the mechanism 102 for moving the buildplatform 22 in one embodiment may be configured to provide multipletending positions at different orientations, such as a first tendingposition that faces downward (i.e., 180° rotation from the buildposition 22 as shown in FIGS. 37 and 62), a second tending position thatfaces laterally outward (i.e., a 90° rotation from the build position 22as shown in FIGS. 37 and 62), and/or a third tending position at adifferent angular orientation (e.g., 135° rotation from the buildposition 22 as shown in FIGS. 37 and 62). In a further embodiment, themechanism 102 for moving the build platform 22 may be configured toprovide the tending position at any desired orientation selectable bythe user, and the mechanism 102 may be manually controlled. Anycombination of tending positions may be provided by the structuresdescribed herein and other embodiments of mechanisms 102 for moving thebuild platform 22 between the build position and the tending position.

In one embodiment, as shown in FIGS. 36 and 37, the system 10 andapparatus 12 may be used to produce multiple objects 11 simultaneously,including multiple objects that are different from each other and havedifferent build times, build requirements, and/or build heights. Asdescribed herein, the apparatus 12 and the deposition mechanism 30according to various embodiments is capable of producing multipleobjects 11 simultaneously, including multiple objects 11 on the samebuild platform 22 or multiple objects 11 on different build platforms 22supported by the same support assembly 20. In the apparatus 12 of FIGS.31-46, the multiple objects 11 can be built with the build platform 22in the build position, as shown in FIG. 37. When a tending operation isnecessary on one or more of the objects 11, the build platform 22 can bemoved to the tending position, as shown in FIG. 36, and the tendingoperation may be performed. FIG. 36 illustrates a tending operation inthe form of removal of one of the objects 11 for which building iscomplete, and it is understood that additional tending operations may beperformed on any of the objects 11, including the objects 11 not removedat this stage. When the tending operation is complete, the buildplatform 22 can be returned to the build position, as shown in FIG. 37,which illustrates the apparatus 12 continuing to build the two remainingincomplete objects 11. This permits different objects to besimultaneously manufactured.

The track 14 in the embodiment of FIGS. 31-46 is configured to be “open”to allow a deposition mechanism 30 (such as the autonomous unit 90) toengage and disengage with the track 14 as desired. The track 14 may beconsidered to have an open end at one or both ends, where the depositionmechanism 30 can be engaged and disengaged with the track 14. As shownin FIGS. 41A-42, the base frame 19 provides an opening 104 definedbetween two vertical columns 105 at one or both ends of the track 14 topermit the deposition mechanism 30 to engage with the track through thebase frame 19. The opening 104 is also present between the rails 15 ofthe track 14. The rails 15 of the track 14 shown in FIGS. 31-46 extendoutwardly beyond the opening 104 and/or beyond the adjacent portion ofthe base frame 19 and have ends 106 that are tapered on one or moresurfaces to ease engagement of the carriage 32 with the track 14. Thecarriage 32 has a track engagement mechanism 109 that is configured toengage the track 14 to permit movement of the deposition mechanism 30along the track 14. The track engagement mechanism 109 in the embodimentof FIGS. 31-46 includes slots 107 that are configured to receive theends 106 during engagement and to further receive a portion of therespective rail 15 when the carriage 32 is engaged with the track 14.The rails 15 in the embodiment of FIGS. 31-46 each have a flange orother outwardly extending portion 108 that is received in the slot 107,and the track engagement mechanism 109 has wheels, rollers, sliders,gears, sprockets or other engagement structures positioned within theslots 107 and engaging the rails 15 on multiple surfaces, including thebottom and/or inner sides of the outwardly extending portion 108. Asshown in FIGS. 41A-B, the track engagement mechanism 109 in theembodiment of FIGS. 31-46 includes rollers 119 that engage the top andinner surfaces of the rails 15 and the undersides of the outwardlyextending portions 108 to stabilize the carriage 32 with respect to thetrack 14. The locomotion of the carriage 32 along the track 14 isprovided by the track engagement mechanism 109, which includes alocomotion mechanism that engages the track 14, such as wheels, gears,sprockets, etc. In one embodiment, the deposition mechanism 30 includesa circular gear that engages a linear gear on the or each rail 15 todrive motion of the carriage 32 along the track 14. In otherembodiments, the locomotion of the carriage 32 along the track 14 may beprovided by powered wheels 117 or by linear induction motors, amongother mechanisms. The track engagement mechanism 109 in one embodimentfurther may have one or more electrical contacts (not shown) forengaging and drawing power from the bus bar(s) 101. The depositionmechanism 30 may be powered by other mechanisms, including an internalpower source, a temporary umbilical power connection, and/or acontactless inductive power supply. Other track engagement mechanisms109 may be used in other embodiments, including different locomotionmechanisms, and it is understood that the track 14 and the trackengagement mechanism 109 may be designed in a complementary manner.

The deposition mechanism 30 in FIGS. 31-46 is configured to be anautonomous unit 90 that may be moveable independently of the track 14 insome circumstances, as described herein with respect to FIG. 28. FIGS.40-41B illustrate movement of the deposition mechanism 30 independentlyof the track 14 and engagement of the deposition mechanism 30 with thetrack 14. As illustrated in FIG. 42, multiple deposition mechanisms 30can be used on the track 14 simultaneously. Such multiple depositionmechanisms 30 may be configured for making multiple passes in oppositedirections or for making a single pass. For example, a depositionmechanism 30 may engage with one end of the track 14, make a single passof the build area 13, and then exit the track 14 at the opposite end toeither move along to a different task (e.g., another apparatus) or tore-engage the track 14 again at the first end. It is contemplated that acontinuous train of deposition mechanisms 30 could sequentially pass thebuild area 13, with each deposition mechanism 30 making a single passand returning to re-engage the track 14 in order to make another pass.In a further embodiment, the apparatus 12 may use a mix of depositionmechanisms including autonomous units 90 that can be disengaged from thetrack 14 and non-autonomous and/or permanent deposition mechanisms 30that cannot be readily disconnected from the track 14.

As described above, the deposition mechanism 30 may be moveableseparately and independently from the track 14 in the embodiment ofFIGS. 31-46, where the deposition mechanism 30 is provided as anautonomous unit 90. In this embodiment, the deposition mechanism 30 usesa ground engagement mechanism for support and locomotion independentlyof the track 14. The ground engagement mechanism in the embodiment ofFIGS. 31-46 uses the wheels 117 for locomotion independently from thetrack 14, e.g., on the surface on which the apparatus 12 sits. Theground engagement mechanism in FIGS. 31-46 also includes stabilizers 118on the front and rear sides of the wheels 117 to stabilize thedeposition mechanism 30 and resist tipping during movement by the wheels117 apart from the track 14. In this embodiment, the stabilizers 118 areretractable when not needed, i.e., the stabilizers 118 are moveablebetween an extended position, shown in FIGS. 33 and 39, for use inmovement apart from the track 14 and a retracted position, shown inFIGS. 31, 32, and 38, when the deposition mechanism 30 is engaged withthe track 14. The stabilizers 118 may include additional wheels,casters, sliders, or other structures to enable ground engagement whilein motion. In other embodiments, the deposition mechanism 30 may includedifferent ground engagement mechanism(s), including tracks, moveablelegs, or other such structures.

The deposition mechanism 30 in the embodiment of FIGS. 31-46 has avertical adjustment mechanism 120 that is configured for adjusting theposition of the applicator 40 and/or other components of the depositionmechanism 30 in the vertical direction, i.e., parallel to the builddirection in the embodiment illustrated. This configuration differs fromthe configurations illustrated in FIGS. 8-11 and 15-18, where verticaladjustment is performed by adjusting the position of the build platform22. The deposition mechanism 30 in FIGS. 31-46 has a bottom portion 121that is engaged with the track 14 and/or the ground and a top portion122 that is supported by the bottom portion 121 and is moveable in thevertical direction with respect to the bottom portion 121. The topportion 122 includes at least the applicator 40, the supply 34 offlowable material 36, and the outlets 54 in the embodiment of FIGS.31-46, such that at least these components move in the verticaldirection with the top portion 122. The vertical adjustment mechanism120 moves the top portion 122 with respect to the bottom portion 121. Inthe embodiment of FIGS. 31-46, the vertical adjustment mechanism 120includes two lifts 123 on opposite sides of the deposition mechanism 30.These lifts 123 may include telescoping structure and may be powered bya variety of different mechanisms, including hydraulic or pneumaticcylinders, jack screws, sprocket/chain drive, gears, etc. In otherembodiments, the build platform 22 of FIGS. 31-46 may additionally oralternately be configured for vertical adjustment as described elsewhereherein. For example, the build platform 22 is not configured forvertical adjustment in the embodiment of FIGS. 31-46, but may be soconfigured in other embodiments, in addition to or instead of thevertical adjustment of the deposition mechanism 30. In one embodiment,both the build platform 22 and the deposition mechanism 30 may beconfigured for vertical adjustment, to further increase the potentialvertical size of an object 11 to be built. In this configuration, thebuild platform 22 may be configured for vertical adjustment only whenthe vertical adjustment range of the deposition mechanism 30 isinsufficient for the build requirements, or vice-versa.

The build platform 22 may be configured for movement to permitproduction of larger and/or more numerous objects than would be enabledby the size of the track 14 in some embodiments. For example, in oneembodiment, shown in FIGS. 48A-B, the build platform 22 is provided on asupport platform 24 that has multiple build platforms 22 and is moveableto selectively position different build platforms 22 in the build area13 for production of different objects 11. As shown in FIG. 48A, thesupport platform 24 is rotatable to position a first build platform 22Awithin the build area 13 to produce a first object 11A, and can thenrotate to place one of three additional build platforms 22B-D in thebuild area 13 to produce one of three other objects 11B-D. Thisconfiguration permits a single deposition mechanism 30 and/or a singletrack 14 with multiple deposition mechanisms 30 to produce objects 11 orportions of objects sequentially. This provides the advantage ofallowing production of one object 11A and then immediately commencingproduction of a second object 11B, without waiting for the completedobject 11A to be removed from the build platform 22A, which can be doneat a later time. This also provides the advantage of allowing one ormore deposition mechanisms 30 to produce a first portion of multipleobjects 11 sequentially, then switching the deposition mechanism(s) 30to produce a different portion of the objects 11 (e.g., that may be madefrom a different material), reducing the number of times that thedeposition mechanism(s) 30 need to be modified or switched during thecourse of producing multiple objects.

As another example, the build platform 22 may be positioned on a supportplatform 24 that is moveable in one or more directions, as shown in FIG.49A-D. In the embodiment of FIGS. 49A-B, the support platform 22 ismoveable laterally (i.e., in the y-direction). In this embodiment, thedeposition mechanism(s) 30 may make one or more passes through the buildarea 13 to produce a first object or portion of an object 11E, then thebuild platform 22 and/or the support platform 24 may be shiftedlaterally to permit production of a second object or portion of anobject 11F. It is understood that FIGS. 49A-B are viewed along thex-direction, i.e., the direction of movement of the deposition mechanism30. The lateral movement shown in FIGS. 49A-B can permit operation ofthe deposition mechanism(s) 30 to build multiple different objects 11 onthe same or different build platforms 22, or to build portions of asingle object 11 that is wider than the build area. In the embodiment ofFIGS. 49C-D, the build platform 22 is moveable horizontally (i.e., inthe x-direction). In this embodiment, the deposition mechanism(s) 30 maybe stationary, and the build platform 22 and/or the support platform maybe shifted horizontally to apply the material 36. In other words,relative movement between the deposition mechanism(s) 30 and the buildplatform 22 is accomplished via movement of the build platform 22 ratherthan movement of the deposition mechanism(s). This configuration may bepracticed with a moveable deposition mechanism 30 as described hereinthat is held stationary for production, and may be connected to an“open” track 14 as described herein, or alternately, this configurationmay be practiced with a permanently stationary deposition mechanism 30.It is understood that in the embodiments of FIGS. 49A-D, the verticaladjustment may be accomplished via adjustment of the height of theapplicator 40, the height of the build platform 22, or a combination. Ina further embodiment, the build platform movement of FIGS. 49A-B may becombined with the movement of FIGS. 49C-D, offering further increase inpotential size of the build area 13.

The apparatus 12 may include a material buildup sensor 124 in oneembodiment, configured to sense buildup of material (e.g., cured resin)on the applicator 40. For example, as shown in FIG. 50, when a roller 42is used, material 129 that is cured by the exposure device 50 mayinadvertently adhere to the roller 42. This adhered material 129 cancause further buildup and negatively affect the quality of the object11. In the embodiment of FIG. 50, a contact member 125 may be positionedso that any discontinuity on the surface of the roller 42 (e.g.,material 129) will cause displacement of the contact member 125, thusallowing the discontinuity to be sensed by a displacement sensor 126configured to sense displacement of the contact member 125. The contactmember 125 in the embodiment of FIG. 50 is shown as a contact roller,but other contact members may be used in other embodiments, such assliders, fibers, etc. Other non-contact based buildup sensors 124 may beused in other embodiments, such as optical sensors,conductivity/resistance sensors, or other sensors. A material buildupsensor 124 as described herein may be incorporated into the depositionmechanism 30 in one embodiment, or may be provided separately from thedeposition mechanism 30 in another embodiment.

In another embodiment, the deposition mechanism 30 may be configuredwith a leveling device 127 to provide greater control over the thicknessof the material 36 applied by the applicator 40. FIGS. 51-52 illustrateone embodiment of an apparatus with a leveling device 127, and FIG. 53illustrates another such embodiment. In the embodiment of FIGS. 51-52,the deposition mechanism 30 includes an applicator 40 in the form of aroller 42 that rotates to carry the flowable material 36 from the supply34 to the build area 13, an exposure device 50 for solidifying theflowable material 36, and a leveling device 127 in the form of aleveling roller 128 located between the roller 42 and the outlet 54 ofthe exposure device 50. In this embodiment, the roller 42 carries theflowable material 36 to the surface 130 to which the material 36 is tobe applied (i.e., the build platform 22 or the surface of the object11), and the leveling roller 128 rotates in the opposite direction fromthe roller 42 to move any excess material 36 back into the supply 34.The movement of the carriage 32 causes the exposure device 50 tosolidify the material 36 after the material 36 has passed the levelingroller 128, and the spacing between the leveling roller 128 and thesurface 130 approximately sets the thickness of the applied layer 38. Asshown in FIG. 52, when there is no surface 130 for application of thematerial 36, the rotation of the leveling roller 128 pushes all of thematerial 36 back into the supply 34. It is understood that increasedadherence between the material 36 and the surface 130 may assist informing the object 11 using a deposition mechanism 30 as shown in FIGS.51-52, as an air gap exists between the applied material 36 and thedeposition mechanism 30 at the intersection point between the waves 53and the material 36. In this embodiment, the application site 41 may bespaced from the exposure site 51, and it is understood that the outlet54 may be aimed in the leading direction as described herein in order tomove the exposure site 51 at or nearer to the application site 41. Thedeposition mechanism 30 further includes a second roller 42 and levelingroller 128 on the opposite side of the carriage 32 (i.e., the left sidein FIGS. 51 and 52). The second roller 42 does not spin when trailingthe application site 41 to avoid moving excess material 36 toward thesurface 130. When the carriage 32 moves in the opposite direction (i.e.,right to left in FIGS. 51-52), the second (leading) roller 42 rotatesand the trailing roller 42 is still. The deposition mechanism 30 inFIGS. 51-52 can therefore apply the material 36 while traveling in twoopposite directions.

FIG. 53 illustrates another embodiment of a deposition mechanism 30 thatuses a leveling device 127 in the form of two leveling rollers 128. Inthis embodiment, the applicator 40 is in the form of a roller 42 thatcarries the material 36 toward the surface 130, and the leveling roller128 on the leading side rotates the opposite direction as the roller 42to remove excess material 36 from the roller 42. The spacing between theroller 42 and the leveling roller 128 approximately sets the thicknessof the applied layer 38. The deposition mechanism 30 includes a secondleveling roller 128 on the opposite side of the carriage 32 (i.e., theleft side in FIG. 53) that performs the leveling function when thecarriage 32 is moving in the opposite direction (i.e., right to left inFIG. 53). Additionally, the trailing leveling roller 128 provides thefurther function of removing unsolidified material (e.g., uncured resin)from the surface of the applied layer 38 after exposure. It isunderstood that the roller 42 will rotate in the opposite direction whenthe carriage is moving in the opposite direction. The depositionmechanism 30 in FIGS. 51-52 can therefore apply the material 36 whiletraveling in two opposite directions. The deposition mechanism 30further includes a plurality of wipers or squeegees 131 configured forwiping excess material 36 from various surfaces, including the surfaceof the roller 42, the surfaces of the leveling rollers 128, and thesurface of the applied layer 38. The deposition mechanism 30 may alsoinclude a vacuum squeegee (not shown) or other vacuum-based materialremoval device as described herein, trailing the final wiper 131. Thisvacuum device may further include a recovery tank for storing unusedmaterial 36 removed by the vacuum device, and it is understood that anyof the vacuum-based material removal devices described herein (includingvacuum squeegees 82) may include such a recovery tank.

The exposure device 50 and associated structures for transmission anddirection of the electromagnetic waves 53 may be configured foradjustability to provide improved performance and/or versatility to thedeposition mechanism 30. Such adjustability may include adjustability inthe selection, arrangement, power output, aiming direction, and/or otheraspects and properties of the exposure device 50 and associatedstructures (including the outlets 54). FIGS. 54-61B illustrate variousembodiments providing such adjustability, and it is understood thataspects of the embodiments of FIGS. 54-61B may be used in combinationwith each other and with other embodiments described herein, includingother adjustable configurations (and applications thereof) alreadydescribed herein.

FIG. 54 illustrates one embodiment an arrangement of the array 55 of theoutlets 54 of the exposure assembly 60 that can provide improvedresolution in part production. The outlets 54 in the embodiment of FIG.54 are staggered with respect to each other, such that each outlet 54 ofthe array 55 is overlapped laterally (i.e., in the y-direction) by atleast one other outlet 54. As shown in FIG. 54, all outlets 54 otherthan the outlets 54 on opposite ends of the array 55 are overlapped onboth edges by other outlets 54. This arrangement permits the lateral(y-direction) extremities of the exposure area to be more preciselyselected, improving the resolution of the exposure assembly 60. Thestaggering of the outlets 54 also permits a greater number of outlets 54to be placed into a given lateral width as compared to a single row,thus improving the total power output of the array 55.

FIG. 55 illustrates an embodiment of an array 55 of the outlets 54 ofthe exposure assembly 60 that are configured for positional adjustmentin the y-direction. In one embodiment, this positional adjustment may beaccomplished by mounting the array 55 on a structure that is configuredfor translational/sliding movement in one embodiment, which slidingmovement may be actuated by a piston, jack screw, or other structureconfigured for one-dimensional movement. In another embodiment, thispositional adjustment may be accomplished by mounting the array 55 on astructure that is configured for angular/tilting movement, which may beactuated by a piston, jack screw, or other structure configured to raiseand lower one or both lateral ends of the array 55. In a furtherembodiment, the outlets 54 may be adjustable individually or in discretegroups or clusters. The outlets 54 may further be configured for rapidreciprocation in the y-direction, permitting a single outlet 54 todirect waves 53 at an area that is enlarged in the y-direction. Thisy-direction adjustment and/or reciprocation permits the lateral(y-direction) extremities of the exposure area to be more preciselyselected, improving the resolution of the exposure assembly 60. It isunderstood that the array 55 may include a larger number of rows and/ordifferent offset arrangements in other embodiments.

FIG. 56 illustrates an embodiment of an array 55 of the outlets 54 ofthe exposure assembly 60 that are configured for adjustment in outputpower. This adjustment in output power may be accomplished by varyingthe output power of the exposure device 50. In one embodiment, theadjustment in output power may be configured to adjust the size of theexposure area 58 of each outlet 54, thereby permitting the lateral(y-direction) extremities of the exposure area to be more preciselyselected, improving the resolution of the exposure assembly 60. As seenin FIG. 56, the size of the exposure area 58 may be increased ordecreased (indicated by broken lines) by increasing or decreasing theoutput power, respectively. In another embodiment, the adjustment inoutput power may be customized to the properties of the flowablematerial 36, as some materials 36 may require larger or smaller amountsof power for solidification. It is understood that other factors, suchas travel speed of the deposition mechanism 30, may influence thedesired output power.

FIG. 57 illustrates an embodiment of an array 55 of the outlets 54 ofthe exposure assembly 60 that are configured such that a first subset132 of the array 55 is configured for emitting waves 53 having a firstproperty and a second subset 133 of the array is configured for emittingwaves 53 having a second property. In one embodiment, the first andsecond subsets 132, 133 may be configured for emitting waves havingdifferent power output levels, permitting significantly greaterversatility in production. For example, the first subset 132 may includesmaller outlets 54 (e.g., smaller diameter optical fibers 61) withrelatively smaller power output levels that are more tightly packedtogether, to permit greater y-direction resolution for criticaldimensions, and the second subset 132 may include larger outlets 54(e.g., larger diameter optical fibers 61) with relatively larger poweroutput levels to permit more rapid solidification for filling the bodyof an object. The different power outputs may be achieved by connectingthe outlets 54 of the different subsets 132, 133 to different exposuredevices 50, connecting the outlets 54 of the different subsets 132, 133to a single exposure device 50 that is capable of power variation, or bythe entrance ends 62 of the second subset 133 receiving waves 53 emittedby a larger number of pixels (if a DLP projector is used) due to theirlarger size. A combination of outlets 54 from different subsets 132, 133(including laterally overlapping outlets 54) may be activated to permitfurther process variability, such as further increased exposure powerand/or a combination of high power for the middle portions of the object11 and finer resolution at the edges of the object 11. In an alternateembodiment, some of these benefits may be achieved using subsets 132,133 of smaller and larger diameter optical fibers 61 without having anydifference in power output between the two subsets 132, 133. In anotherembodiment, the outlets 54 of the first and second subsets 132, 133 maybe connected to different exposure devices that emit differentwavelengths of waves 53 that may cure different types of materials 36 orto cure one material 36 at different rates. It is understood that alarger number of subsets 132, 133 with further different properties maybe used in other embodiments, and that the waves 53 emitted by eachsubset may have multiple properties differing from each other.

FIGS. 61A and 61B illustrates an embodiment of a deposition mechanism 30that uses multiple outlets 54 or arrays 55A-C of outlets 54 that can beswitched selectively. In one embodiment, multiple arrays 55A-C ofoutlets 54 may be mounted on a mounting structure 135 that is rotatableabout an axis (e.g., mounted on a gimbal structure), such that thearrays 55A-C can be selectively aimed toward the exposure site 51. Eacharray 55A-C may be configured differently. For example, the arrays 55A-Cmay be configured to emit waves 53 having one or more differentproperties, e.g., wavelengths, power, or other properties as describedherein, or the arrays 55A-C may have outlets 54 that are sized orarranged differently to produce different resolution ability. Thisconfiguration increases the versatility of the process, as a singledeposition mechanism 30 can operate with different materials 36 thatrequire waves 53 having different properties for solidification anddifferent projects that require different resolution capabilities,similar to the configuration of FIG. 57. It is understood that thesubsets 132, 133 in FIG. 57 may be mounted to be moveable to selectivelyaim each subset 132, 133 toward the exposure site 51 in one embodiment,such as by translational movement and/or by rotational movement as shownin FIGS. 61A-B. In other embodiments, the deposition mechanism 30 mayinclude a different number of arrays 55A-C, and the mounting structure135 may be moveable in a different manner to select among the arrays55A-C.

FIG. 58 illustrates one embodiment of a structure for directing thewaves 53 so that the exposure site 51 is located approximately at theapplication site 41 in one embodiment, or so that the exposure site 51is offset from the application site 41 (ahead or behind the applicationsite 41 in the direction of travel) in another embodiment, as describedherein and illustrated with respect to FIGS. 1, 3, and 4. In thisembodiment, the aim of the outlets 54 is adjustable forwardly andrearwardly in the x-direction. As illustrated in FIG. 58, the outlets 54of the exposure assembly 60 may be configured to be tiltable in oneembodiment, such as by mounting the outlets 54 using a structure (e.g.,braces 65) that is rotatable or pivotable over a range of movement toadvance or retard the exposure site 51. For example, the depositionmechanism 30 may include a mounting structure for the outlets 54 that ismounted on a gimbal to permit single-axis rotation. It is understoodthat the degree of tilting shown in FIG. 58 may be exaggerated comparedto the actual degree of tilting necessary to achieve this purpose inmany embodiments. In another embodiment, the exposure device 50 mayinclude multiple arrays of outlets 54 that are directed at differentangles, where selective activation of the outlets 54 allows the exposuresite 51 to be advanced or retarded. In a further embodiment, the outlets54 may be aimed differently by translational movement in thex-direction. It is understood that the degree of offset of the exposuresite 51 may depend on the properties of the flowable material 36 and thespeed of the deposition mechanism 30, among other factors. Offsettingthe exposure site 51 may improve bonding of the flowable material 36 tothe surface 130 and/or separation of the flowable material 36 from theroller 42. On rollers 42 having greater lengths, contraction of thematerial 36 as it solidifies can pull on the surface of the roller 42 ifthe material 36 is not properly separated from the roller 42, causingdimensional distortion (e.g., bowing outward) of the surface of theroller 42. Offsetting the exposure site 51 can therefore be particularlyadvantageous for such configurations.

FIGS. 59 and 60 illustrate an embodiment of a deposition mechanism 30with an exposure assembly 60 capable of directing the waves 53 offsetfrom the application site 41. In the embodiment of FIGS. 59 and 60, theaim of the outlets 54 is adjusted along the direction of travel of thedeposition mechanism as the applicator 40 passes the application site 41to focus the waves 53 on a defined point 134 within the build area 22 asthe applicator 40 passes the defined point 134, to increase the exposuretime of the defined point 134. As illustrated in FIG. 59, the exposureassembly 60 is configured for continuously adjusting the aim of theoutlets 54 rearwardly in the travel direction so that the aim of theoutlets 54 tracks the defined point 134 and continue to focus on thedefined point 134 after the applicator 40 (i.e., the apex of the roller42 in this embodiment) passes the defined point 134. As illustrated inFIG. 60, the exposure assembly 60 is configured for continuouslyadjusting and re-adjusting the aim of the outlets 54 forwardly in thetravel direction so that the aim of the outlets 54 tracks the definedpoint 134 in advance of the applicator 40 and continue to focus on thedefined point until the applicator 40 (i.e., the apex of the roller 42in this embodiment) arrives at the defined point 134. This createsmoments of stationary exposure at the defined point 134, and it isunderstood that the start/stop aim angles may be based on factors suchas build speed and the properties of the material 36. It is understoodthat the embodiments in FIGS. 59 and 60 may be combined so that the aimof the outlets 54 tracks the defined point 134 both in advance of andbehind the arrival of the applicator 40 at the defined point 134.

In a further embodiment, an apparatus 12 as described herein may beenclosed within a sealed chamber that may be temperature controlled,pressure-controlled, humidity-controlled, and/or filled with a specificgas (including mixtures of gases). Temperature, pressure, and humiditycontrol may be able to influence build speed and thereby improveefficiency. Additionally, the apparatus 12 has the ability to buildhollow, sealed objects 11, and thus, selection of the environmental gasmay permit production of a hollow, sealed object 11 filled with aspecified gas. For example, such an object 11 filled with an inert gasmay be useful, e.g., for aerospace applications.

The system 10 also includes a controller 100 that is configured tocontrol and/or monitor the operation of one or more mechanisms of theapparatus 12, including numerous examples described herein. In oneembodiment of the invention, controller 100 may be implemented with acomputer system, such as computer 2602. Computer 2602 includes a centralprocessor 2604 that controls the overall operation of the computer and asystem bus 2606 that connects central processor 210 to the componentsdescribed below. System bus 2606 may be implemented with any one of avariety of conventional bus architectures.

Computer 2602 may include a variety of interface units and drives forreading and writing data or files. For example, computer 2602 mayinclude a memory interface 2608 coupling a memory drive 2610 to systembus 2606. Memory drive 2610 may be implemented with physical memorydevice, magnetic memory device, optical memory device or other type ofmemory device. Memory drive 2610 may store data, CAD files, and otherelectronic files that are used to produce three-dimensional objects asdescribed herein. A system memory 2612 may be included and implementedwith a conventional computer readable medium memory having a read onlymemory section that stores a basic input/output system (BIOS) and arandom access memory (RAM) that stores other data and files. Memorydrive 2610 and system memory 2612 may both contain computer-executableinstructions designed to be executed by processor 2604. In someembodiments, one or more control programs for operating one or moreapparatuses 12 and/or multiple components (e.g., multiple depositionmechanisms 30) within each apparatus 12 may be stored in memory drive2610 and/or system memory 2612.

Computer 2602 may include additional interfaces for connectingperipheral devices to system bus 2606. For example, computer 2602 mayalso include a network interface 2614 that couples system bus 2602 tolocal area network (LAN) 2616. LAN 2616 may have one or more of thewell-known LAN topologies and may use a variety of different protocols,such as Ethernet. A wide area network (WAN) 2618, such as the Internet,may also be accessed by computer 2602. FIG. 26 shows a router 2620 thatmay connect LAN 2616 to WAN 2618 in a conventional manner. A server 2622is shown connected to WAN 204. Of course, numerous additional servers,computers, handheld devices, personal digital assistants, telephones andother devices may also be connected to WAN 2618. In some embodiments,server 2622 stores data, CAD files, control programs and/or otherelectronic files that may be accessed by computer 2602 and used toproduce three-dimensional objects as described herein.

Various embodiments are described herein with various combinations offeatures and components. It is understood that the features andcomponents of each of the various embodiments described herein may beincorporated into other embodiments described herein.

The use of the system and apparatus described herein provides benefitsand advantages over existing technology. For example, consumable cost isgreatly decreased, as the apparatus generates little waste and does notrequire maintaining a large vat of material to be solidified formanufacturing, as do many current technologies. Additionally, thestructure of the apparatus does not dictate any specific size limits,and the apparatus may be configured to create an object that issignificantly larger than existing technologies. The length of the trackand the width of the applicator can be increased as desired withoutnegatively affecting performance, and the size of the room in which theapparatus sits becomes the limit of the size of the apparatus. Further,the apparatus may be configured for manufacturing an object or multipleobjects many times faster than any existing technology. The apparatusalso provides the ability to manufacture objects from multiplematerials, including objects that have removable support structure thatis made from a material different from that of the main object.Production of objects from multiple materials that require differentexposure sources is enabled as well. The apparatus further provides theability to manufacture functional objects, such as a window or othertransparent object, or a conductive object. Still further, objectsmanufactured using the apparatus described herein may not requiredraining liquid material from any internal cavities of the finishedobject, which may require drilling a hole for drainage. The apparatus isalso capable of producing clean, dry, and fully-cured objects, whichincreases production efficiency. The modular configuration of theapparatus also great versatility, customizability, and other benefits.

Additional advantages are provided by the configuration of thedeposition mechanism 30 as an autonomous unit 90 with a verticaladjustment mechanism 120, in combination with an open-ended track 14that can be engaged and disengaged by the unit 90 and a build platform22 associated with the track 14 and configured for manufacturing of anobject 11 in a downward layer-by-layer technique. This configurationpermits multiple deposition mechanisms 30 to operate on the same track14 to apply multiple layers to one or more objects 11 simultaneously.Multiple deposition mechanisms 30 operating on the same track 14 maycombine to build one or more objects 11 or may build multiple objects 11separately and simultaneously on the same build platform 22. Thisconfiguration also enables building multiple objects of the same ordifferent materials in separate locations on the same build platform 22in a rapid manner. This configuration also facilitates maintenance ofthe deposition mechanism 30, as an autonomous unit 90 can be removedfrom the production process for maintenance quickly and easily, and mayalso be quickly and easily replaced with another unit 90 to achievesubstantially uninterrupted production. A system including multiple suchunits 90 can operate with a number of different build platforms 22, suchas in a large production facility, where the units 90 can be assignedand re-assigned to specific build areas 13 as needed for optimizedproduction. Still other benefits and advantages over existing technologyare provided by the systems, apparatuses, and methods described herein,and those skilled in the art will recognize such benefits andadvantages.

Several alternative embodiments and examples have been described andillustrated herein. A person of ordinary skill in the art wouldappreciate the features of the individual embodiments, and the possiblecombinations and variations of the components. A person of ordinaryskill in the art would further appreciate that any of the embodimentscould be provided in any combination with the other embodimentsdisclosed herein. It is understood that the invention may be embodied inother specific forms without departing from the spirit or centralcharacteristics thereof. The present examples and embodiments,therefore, are to be considered in all respects as illustrative and notrestrictive, and the invention is not to be limited to the details givenherein. The terms “first,” “second,” “top,” “bottom,” etc., as usedherein, are intended for illustrative purposes only and do not limit theembodiments in any way. In particular, these terms do not imply anyorder or position of the components modified by such terms.Additionally, the term “plurality,” as used herein, indicates any numbergreater than one, either disjunctively or conjunctively, as necessary,up to an infinite number. Further, “providing” an article or apparatus,as used herein, refers broadly to making the article available oraccessible for future actions to be performed on the article, and doesnot connote that the party providing the article has manufactured,produced, or supplied the article or that the party providing thearticle has ownership or control of the article. Accordingly, whilespecific embodiments have been illustrated and described, numerousmodifications come to mind without significantly departing from thespirit of the invention.

1. An assembly comprising: a support assembly comprising a buildplatform defining a build area for producing a three-dimensional objecton the build platform; a track extending through the build area, whereinthe track has an open end; and a deposition mechanism engaged with thetrack, the deposition mechanism comprising a carriage configured formovement along the track through the build area, a supply of a flowableresin mounted on the carriage, an applicator in communication with thesupply of flowable resin and configured for application of the flowableresin, and an exposure device mounted on the carriage and configured foremitting electromagnetic waves to solidify the flowable resin, whereinthe deposition mechanism comprises a track engagement mechanismconfigured for releasably engaging the track and moving the depositionmechanism along the track for producing the three-dimensional object,and wherein the deposition mechanism is engageable with anddisengageable from the track by passing through the open end of thetrack, and the deposition mechanism further comprises a groundengagement mechanism configured to move the deposition mechanismseparately from the track when the deposition mechanism is disengagedfrom the track.
 2. The assembly of claim 1, wherein the groundengagement mechanism comprises wheels configured for movement of thedeposition mechanism separately from the track.
 3. The assembly of claim1, wherein the track comprises first and second rails on opposite sidesof the build platform, wherein the first and second rails are configuredto be engaged by the deposition mechanism and support the depositionmechanism for movement through the build area, and wherein an opening isdefined between the first and second rails at the open end, such thatthe deposition mechanism can engage with and disengage from the track bypassing through the opening.
 4. The assembly of claim 3, wherein thetrack engagement mechanism comprises rollers configured to engage innerand outer surfaces of the first and second rails and gears configured todrive movement of the deposition mechanism along the first and secondrails.
 5. The assembly of claim 1, wherein the track extends below thebuild platform and the build area is defined below the build platform.6. The assembly of claim 1, wherein the deposition mechanism furthercomprises an onboard power source to power operation of the depositionmechanism.
 7. The assembly of claim 1, wherein the deposition mechanismfurther comprises a processor configured to control movement of thecarriage and operation of the applicator and the exposure device in anautonomous manner, according to computer-executable instructions.
 8. Theassembly of claim 1, wherein the ground engagement mechanism furthercomprises extendible stabilizers, wherein the stabilizers are configuredto be movable between an extended position for stabilizing thedeposition mechanism when the deposition mechanism is disengaged fromthe track and a retracted position when the deposition mechanism isengaged with the track.
 9. The assembly of claim 1, wherein the buildplatform is moveable between a build position and a tending position,wherein the build platform faces toward the track in the build positionto permit production of the three dimensional object by the depositionmechanism located on the track, and wherein the build platform facesaway from the track in the tending position to permit a tendingoperation to be performed on the three dimensional object.
 10. Theassembly of claim 9, wherein the support assembly further comprises arotating base configured for rotation on an axis and a support platformextending from the rotating base in a direction parallel to the axis,wherein the build platform is supported by the support platform, andwherein the build platform is moveable between the build position andthe tending position by rotation of the rotating base, which causes thesupport platform to orbit the axis. 11-17. (canceled)
 18. An assemblycomprising: a support assembly comprising a build platform defining abuild area for producing a three-dimensional object on the buildplatform; and a track extending through the build area, wherein thetrack is configured for supporting a moveable deposition mechanism topass through the build area for producing the three-dimensional objecton the build platform using a flowable resin in a layer-by-layertechnique, wherein the build platform is moveable between a buildposition and a tending position, wherein the build platform faces towardthe track in the build position to permit production of the threedimensional object by the deposition mechanism located on the track, andwherein the build platform faces away from the track in the tendingposition to permit a tending operation to be performed on the threedimensional object.
 19. The assembly of claim 18, wherein the supportassembly further comprises a rotating base configured for rotation on anaxis and a support platform extending from the rotating base in adirection parallel to the axis, wherein the build platform is supportedby the support platform, and wherein the build platform is moveablebetween the build position and the tending position by rotation of therotating base, which causes the support platform to orbit the axis. 20.The assembly of claim 19, wherein the rotating base is positioned at afirst end of the support platform, and the support assembly furthercomprises a second rotating base at a second end of the support platformopposite the first end, and wherein the second rotating base is alsoconfigured for rotation on the axis, such that the rotating base and thesecond rotating base rotate in unison to move the build platform betweenthe build position and the tending position.
 21. The assembly of claim19, wherein the rotating base is configured to rotate 180° in moving thebuild platform between the build position and the tending position. 22.The assembly of claim 18, wherein the build platform is moveable betweenthe build position and the tending position by rotation.
 23. Theassembly of claim 18, further comprising the deposition mechanism,wherein the deposition mechanism comprises a carriage configured formovement along the track, an applicator in communication with the supplyof flowable resin, wherein the applicator is mounted on the carriage andconfigured for applying the flowable resin to an application site withinthe build area to produce a three-dimensional object on the buildplatform as the carriage passes through the build area.
 24. The assemblyof claim 18, wherein the track extends below the build platform and thebuild area is defined below the build platform.
 25. The assembly ofclaim 18, wherein the build platform is further moveable between thebuild position and a plurality of tending positions, wherein the buildplatform faces at different orientations in each of the plurality oftending positions. 26-31. (canceled)
 32. An apparatus comprising: acarriage configured for movement through a build area defined by a buildplatform; a supply of a flowable resin mounted on the carriage; anapplicator in communication with the supply of flowable resin, whereinthe applicator is mounted on the carriage and configured for applyingthe flowable resin to an application site within the build area toproduce a three-dimensional object on the build platform as the carriagepasses through the build area; a vertical adjustment mechanismconfigured for adjusting a vertical position of the applicator relativeto the carriage; and an exposure device mounted on the carriage andconfigured for emitting electromagnetic waves through an outlet towardan exposure site within the build area to solidify applied resin appliedby the roller to produce the three-dimensional object.
 33. The apparatusof claim 32, wherein the apparatus is automated, such that the carriagehas a processor configured to control movement of the carriage accordingto computer-executable instructions.
 34. The apparatus of claim 33,wherein the carriage has a memory storing the computer-executableinstructions.
 35. The apparatus of claim 33, wherein the carriage has areceiver configured for receiving the computer-executable instructionsfrom an external device and a transmitter configured for transmittinginformation to the external device.
 36. The apparatus of claim 32,wherein the vertical adjustment mechanism is further configured foradjusting a vertical position of the supply and the outlet of theexposure device along with the applicator as a single unit.
 37. Theapparatus of claim 32, wherein the carriage has wheels configured formoving on a flat surface and a track engagement mechanism configured forengaging a track that extends through the build area and moving thecarriage along the track.
 38. The apparatus of claim 32, wherein thecarriage has a track engagement mechanism configured for engaging atrack that extends through the build area and moving the carriage alongthe track.
 39. An apparatus comprising: a carriage configured formovement through a build area defined by a build platform; a supply of aflowable resin mounted on the carriage; an applicator in communicationwith the supply of flowable resin, wherein the roller is rotatablymounted on the carriage and configured for rotating to carry theflowable resin to an application site within the build area forapplication to produce a three-dimensional object on the build platformas the carriage passes through the build area; an exposure devicemounted on the carriage and configured for emitting electromagneticwaves through an outlet toward an exposure site within the build area tosolidify applied resin applied by the roller to produce thethree-dimensional object; and a processor configured to control movementof the carriage and operation of the applicator and the exposure devicein an autonomous manner, according to computer-executable instructions.40. The apparatus of claim 39, further comprising a memory storing thecomputer-executable instructions.
 41. The apparatus of claim 39, whereinthe computer-executable instructions further comprise instructions forproducing the three-dimensional object in a layer-by-layerconfiguration.
 42. The apparatus of claim 39, further comprising areceiver configured for receiving the computer-executable instructionsfrom an external device and a transmitter configured for transmittinginformation to the external device.
 43. The apparatus of claim 39,wherein the carriage has wheels for moving on a flat surface and a trackengagement mechanism configured for engaging a track that extendsthrough the build area and moving the carriage along the track.
 44. Theapparatus of claim 39, wherein the carriage has a track engagementmechanism configured for engaging a track that extends through the buildarea and moving the carriage along the track, and wherein the trackengagement mechanism further includes electrical contacts to permit theapparatus to draw electrical power from the track in a bus arrangement.45. The apparatus of claim 39, further comprising a vertical adjustmentmechanism configured for adjusting a vertical position of the applicatorrelative to the carriage. 46-58. (canceled)